IOCL PARADIP REFINERY : salient features

 15 MMTPA grassroots refinery.

 Nelson complexity factor of 12.2
 capable of processing broad basket of crude including
cheaper High Sulphur Heavy crudes.
 production of fuels of premium grade Euro-IV quality.
 distillate yield from the refinery is expected to be best in
class with 81.1% with no black oil production.
 Energy index of the refinery is expected to be 50 MBN (Million
BTU per barrel per NRGF) - one of the best in the country
(Panipat MBN for 2011-12 was 52).
 State-of-the-art technologies from various technology licensors
across the world.
Paradip Refinery Project
A Sunrise Project For A Sunshine Future
 NELSON Index/ complexity factor
• provides an easy metric for quantifying and ranking the
complexity of different refineries.
• developed in 1960 by Wilbur Nelson.
• refineries that are higher on the Nelson Index are valued
higher relative to their peers e.g. high Nelson Index refineries
may be able to refine inferior quality crude oil,
or
• be capable of producing higher value end products e.g. high
percentage of LPG, light distillates and middle distillates and
low percentage of heavies and fuel oil.
• higher the index, higher is the complexity.
• due to their greater complexity, high Nelson Index refineries
are more costly to build and operate.
 PRODUCT PATTERN

Figures are in ’000 TPA

Crude Intake 15,000 (wt.% on crude)
Propylene + LPG 790 5.2%
MS 3,794 25.3%
SKO/ATF 1,967 13.1%
HSD 5,621 37.5%
Total Distillate 12,172 81.1%
Sulphur 268 1.8%
Petcoke 1,219 8.1%
Fuel & Loss 1,356 9.0%

Products will mainly be consumed in domestic market except some

quantity of MS which will be exported.
 MAJOR PROCESS UNITS, CAPACITIY & LICENSOR
PROCESS UNITS CAPACITY (’000 TPA) PROCESS LICENSOR
Primary Processing Unit
Atmospheric & Vacuum Unit (AVU) 15,000 Open art by FWEL
Secondary Processing Units
INDMAX (Fluidized Catalytic Cracking or FCC) 4,170 IOC R&D
Delayed Coking Unit (DCU) 4,400 Foster Wheeler, USA
VGO Hydro Treating Unit (VGO-HDT) 5,400 Axens, France
Other Major Processing Units
Diesel Hydro Treating Unit (DHDT) 5,200 Shell Global, Netherlands
Naphtha Hydro-Treating/Catalytic Refor (NHT/CCR) 3,900 / 2,900 UOP, USA
Alkylation Unit 650 ExxonMobil, USA
Butane Isomerization Unit (Butamer) 300 UOP, USA
Propylene Recovery Unit (PRU) 1900 Basell, Italy
Sulphur Recovery & Tail Gas Treating (SRU/TGTU) 2 x 525 TPD Black & Veatch, USA
Kero / FCC LPG/ FCC Gasoline Treating Units 1,200/1,850/400 Merichem, USA
SR LPG Treating unit 210 UOP, USA
Sulphuric Acid Regeneration Unit 185 TPD MECS
Sour Water Stripper (SWS) Train 1/2 402.6 / 228.8 TPH Open Art
Amine Regeneration Unit (ARU) Train 1/2 478.8 / 947.9 TPH Open Art
 PROJECT EXECUTION METHODLOGY

IOCL

Managing PMC (FWEL)

EPCM-1 EPCM-2 PMC-3/EPCM-3 EPCM-4 EPCM-7 PMC-5 PMC-8 PMC-9 PMC-6 PMC-10 PMC-11
FWEL UHDE JACOBS/TOYO TOYO DCPL TCIL PDIL FEDO SPAN EIL EIL

DHDT, DCU, Indmax Elec. Non- Captive South

BOO-1 BOOT-3 BOOT-4
VGO, Int. Tanks & PRU System Plant Power Jetty
H2+N2 Crude & Water
HCDS Bldg. Finished Intake & Plant & Facilities &
Boilers Crude/
Product Treat.
Tanks Product
Pipelines
LSTK-A LSTK-B LSTK-C Balance of Note:
ESSAR PLL KSS EPCM-1 1. SPM & Associated Facilities is being
implemented by Pipelines Division
AVU, Alkylation, Offsite & CT, DMP,
SR-LPG Butamer Utilities ETP, Flare, 2. Infrastructure development is being directly
Treater SARU, SRU, Fired handled by PDRP Group
Legend:
NHT-CCR, TGTU, FGD Heaters,
PMC: Project Management Consultant
SWS, & Treaters FIM
EPCM: Engg. Procurement Construction Management
ARU
LSTK: Lump Sum Turnkey Contractor
BOO: Build, Own & Operate
BOOT: Build, Own, Operate & Transfer
 ATMOSPHERIC VACUUM UNIT (AVU) : UNIT NO. 010

15 MMTPA / 3,40,822 BPD/ 43,269 TPD

Capacity
(CDU : 15 MMTPA/ VDU : 8.7 MMTPA)

Licensor Open Art by FWEL

Primary separation of crude oils to produce st. run blend

Objective stocks or distillate and feedstock for other downstream
process units

Basrah Light & Oman Export crude (50 wt% each) : light crude
Feed
Kuwait & Maya crude (60 : 40 wt%) : heavy crude

Turndown 50%
ATMOSPHERIC VACUUM UNIT (AVU) : UNIT NO. 010
 ATMOSPHERIC VACUUM UNIT (AVU) : UNIT # 010

UNIT CONFIGURATION

• CRUDE DISTILLATION UNIT (CDU)

• NAPHTHA STABILISATION SECTION (NSU)

• VACUUM DISTILLATION UNIT (CDU)

ATMOSPHERIC VACUUM UNIT (AVU) : UNIT # 010

C3 LPG to Storage
 SR LPG TREATMENT UNIT : UNIT # 011

Capacity 210,000 TPA

Licensor UOP

Remove H2S & mercaptans from untreated LPG streams in an

Objective
amine and caustic Merox system.

• SR LPG ex AVU
Feed
• VGO-HDT LPG

Treated LPG (sent to AVU De- Propaniser for splitting into

Product
propane & butane)

Turndown 50%
SR LPG TREATMENT UNIT : UNIT # 011
 ATF/ KERO TREATMENT UNIT : UNIT # 12

Capacity 1.2 MMTPA of untreated ATF

Licensor Merichem Chemicals & Refinery Services LLC, USA

Objective Remove naphthenic acid & mercaptans from untreated ATF.

Feed Kerosene cut from CDU

Product Treated ATF (sent to ATF storage tank)

Process Extractive mercaptan oxidation technology

 NAPHTHA HYDROTREATER (NHT), NAPHTHA
FRACTIONATION UNIT (NFU) & CCR (P & R) UNITS
(UNIT # 040, 041, 042 & 043)
Capacity 3.960/ 3.068/ 2.980 MMTPA

Licensor UOP, USA

NHT : prepare feed for CCRU with sulphur & nitrogen < 0.5 ppmw
NFU : split hydrotreated naphtha from NHT to Light Naphtha (HGU
feed) & Heavy Naphtha (CCR-P feed)
Objective
CCR-P : produce high octane gasoline & H2 (by-product) in presence
of catalyst
CCR-R : regenerate CCR-P catalyst

Feed SR Naphtha from CDU (mainly)

NHT : hydrotreated naphtha to NFU

Product NFU : LN as feed to HGU & HN as feed to CCR-P
CCR-P : reformate for MS production & H2 to HCDS

Process Extractive mercaptan oxidation technology

 DIESEL HYDROTREATER: UNIT # 13 - 15

Capacity 5.2 MMTPA

Licensor Shell Global

Produce ultra low sulphur diesel (10 ppmw max.) and cetane
Objective
improvement of diesel

• KEROSENE, AGO & VGO from AVU

Feed • Coker Gas Oil from DCU
• HCN, LCO and HCO from FCC

• Diesel product to storage

Product
• Unstabilised Naphtha to AVU

Turndown 50%
DHDT
 DOCUMENTATION

1. PFD & P&IDS

a) Identification of SYSTEMS & SUB-SYSTEMS for each unit to facilitate
mechanical integrity checking of the unit as per P&ID.

a) Preparation of detailed FLUSHING PLAN for each system.

2. Operating & Pocket Manuals

3. Unit plot plans

4. Safety plan

5. SOPs
PFD
P&ID
PLOT PLAN
LIST OF SYSTEMS
MARKED-UP SYSTEM
 ON-GOING ACTIVITIES

Review of graphics

Identification and availability of PPEs

Identification & ensuring availability of tools & tackles.

Follow-up action for catalyst, chemicals, lube oils.

Training

FORMAT I : Intimation regarding system completion

Checklisting FORMAT II : Punch points

FORMAT III :Mechanical completion

 REVIEW OF GRAPHICS
FIELD ACTIVITIES : INSTRUMENTATION

Participation in FAT

Check accessibility to instruments for routine checks and maintenance.

Check that control valves and associated bypass valves have been installed as per
proper flow direction.

FIELD ACTIVITIES : ELECTRICAL

Witness motor trial run of rotary equipment (including all fans) in decoupled
condition; confirm for proper direction of rotation.

FIELD ACTIVITIES : CIVIL

Ensure proper segregation of OWS and CRWS network and marking of manholes

Check floor gradient inside b/limit to avoid water logging

 ON-GOING ACTIVITIES
FIELD ACTIVITIES : MECHANICAL

Visual inspection of piping and layout during construction

Participation in refractory dry out of heaters

Witness fixation of column, vessel, reactor internals.

Carry out/ witness flushing and blowing activities for pipelines including
associated offsite facilities and other UG systems.
Finalizing passivation of cooling water system, degreasing of amine circuit,
acid cleaning of lube oil circuits

Checking associated offsite storage facilities and line up to unit battery limit.

Checking of associated offsite facilities

 Refinery Commissioning Sequence

UTILITIES Raw Water/ Fire Fighting System/ Service Water/ Cooling

&
ETP Tower/ Plant Air & Instrument Air/ OWS/ CRWS/ ETP /DM water

CPP BFW/ Start up fuel (HSD/FO) / 2 GTs & HRSG + 2 UBs/ 1STG/
Steam Network

OFFSITES N2 / LPG unloading /Fuel gas /Flare/Crude tanks /

Product & Intermediate tanks / Process & Other utility Lines

PROCESS AVU/ SR LPG & ATF Treaters

UNITS 1 ARU/ 1 SWS/ 1 SRU/ H2/ HCDS/ NHT/ DHDT/CCRU

BALANCE
VGOHDT/ INDMAX/ DCU/ 2nd ARU & SWS/ 2nd SRU/ Balance of
PROCESS
Power Plant (1GT + HRSG & 2 UBs)/ Alkylation/ Butamer/ SARU
UNITS