OVERVIEW OF

PETROCHEMICALS
&
NAPHTHA CRACKER
T.K.BASAK
GM(PC)
IOCL-RHQ

OVERVIEW OF
PETROCHEMICALS

PRODUCT CATAGORIES

PETROCHEMICALS
MONOMERS

DETERGENTS
SOLVENTS

POLYMERS

Adhesives

TYPES OF POLYMERS

Polymer
Plastics

Thermoplastics

Rubber

Thermosetting

Fibre

Paints /
Adhesives

POLYMERS
Polymeric materials with specific properties and having
different application areas are:
9Plastics: polymer characterized by rigidity & stiffness
having low recoverable deformation.
9Rubber: polymer characterized by flexibility & high
amount of recoverable deformation
9Fibre: polymer having high melting point with high
amount of crystallinity when stretched
9Paints & adhesives: polymer with tackiness enabling good
bond strength

Polymerisation
Chemical reaction by which
polymers are formed
Polymerisation
Addition
(Polyethelenes)

Condensation
(Polyesters)

Techniques
(Polymerisation)
Bulk

Solution

Suspension Emulsion

GRADES OF A GIVEN POLYMER

-To suit application/product requirements

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

Basic Polymer Properties ; PE

Melt Flow Index (MFI)

Density (Crystallinity)
Molecular
(MWD)

weight

distribution

WHY PLASTICS ?

Properties can be altered

to suit the needs

Good strength/weight ratio

Tough & durable

Non toxic

Easy processability

Chemical/Moisture
Resistant

Fire retardant

Do not rust/corrode.

Resistant to microbes

Attractive colours

Good weatherability

Practically maintenance free

Reusable / Recyclable

At Much Cheaper Price !!!

Polymers Per Capita Consumption

a comparison

Kg / Pe rso n

Polymers

30.0
20.0
10.0
0.0

15.0

21.0

4.0

India

China

World

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

KEY POLYMERS
9 POLY ETHYLENE
9 POLY PROPYLENE
9 POLY ESTERS
9 POLYVINYL CHLORIDE
9 POLY STYRENE
9 POLY CARBONATE

MARKET SHARE OF PLASTIC

MATERIALS
POLYMER

% MARKET SHARE

POLY-ETHYLENE

33.5%

POLY-PROPYLENE

19.5%

POLYESTERS

18.0%

POLYVINYL CHLORIDE

BASIC FEED STOCKS

FOR
PETRCHEMICALS
9 ETHYLENE
9 PROPYLENE
9 PARA-XYLENE
9 BUTADIENE

BASIC BUILDING BLOCKS

FOR
PETRCHEMICALS

9 OLEFIN
9 AROMATICS
9 SYNTHESIS GAS

MAJOR SOURCE OF
OLEFINS

9 NAPHTHA CRACKER
9 GAS CRACKER
9 FCC

MAJOR SOURCE OF
AROMATICS

9 NAPHTHA CATALYTIC REFORMING

9 PYROLYSIS GASOLINE FROM
CRACKER

Primary Feed Stock - NAPHTHA

ROUTE

SECONDARY FEED STOCK

/ PRODUCT

AROMATIZATION

B,T,X

CRACKING

C2, C3, C4 & HIGHER

Olefins

FEED STOCK FROM GAS &LPG OF

FCC
C2 OLEFINS
C3 OLEFINS
C4 OLEFINS

FEW STATISTICS
9 WORLD VARGIN NAPHTHA PRODUCTION : MORE
THAN 1 BILLION TONNES PER ANNUM
9 ABOUT 40% OF NAPHTHA PRODUCED IS UTILISED
FOR PRODUCTION PETROCHEMICALS
9 PRODUCTION OF ETHYLENE = 110 MMTPA
9 PRODUCTION OF PROPYLENE = 65 MMTPA
9 AROMATIC RAW MATERIALS = 70 MMTPA
9 IN ASIA, 61% OF ETHYLENE IS PRODUCED FROM
NAPHTHA.

WHY REFINERY PETROCHEMICAL

INTEGRATION
REFINING INDUSTRY FAVOURS INTEGRATION DUE TO
9 SURPLUS NAPHTHA AVAILABILITY
9 GASOLINE COMPOSITION CAHANGES
9 INCREASE BTX RECOVERY FROM REFINERIES
9 SHIFT OF FCC TOWARDS OLEFIN PRODUCTION

WHY REFINERY PETROCHEMICAL

INTEGRATION
PETROCHEMICAL INDUSTRY FAVOURS INTEGRATION
DUE TO
9 TO OBTAIN SECURE, LOW COST FEED SUPPLY
9 ENHANCE BY-PRODUCT STREAM VALUES
9 MINIMIZE COST STRUCTURE

KEY INTERFACES BETWEEN

REFINERY & OLEFIN PLANT
REFINERY TO OLEFIN PLANT
9
9
9
9

DRY GAS
PROPYLENE
N-BUTANE
NAPHTHA

KEY INTERFACES BETWEEN

REFINERY & OLEFIN PLANT

9
9
9
9

OLEFIN PLANT TO REFINERY

C4 RAFFINATE
PYROLYSIS GASOLINE
PYROLYSIS FUEL OIL
HYDROGEN

NAPHTHA CRACKER

PRODUCTS FROM PANIPAT REFINERY COMPLEX

REFINERY
REFINERY

MS
MS

LPG
LPG

SKO/ATF
SKO/ATF

HSD
HSD

NAPHTHA
NAPHTHA

COKE
COKE

LAN

HAN

AROMATIC
AROMATIC
COMPLEX
COMPLEX

NAPHTHA
NAPHTHA
CRACKER
CRACKER

PX
PX

Ethylene
Ethylene

Polymerisation
Polymerisation

Propylene
Propylene

Ethylene
Ethylene
Oxidn.
Oxidn.

Polymerisation
Polymerisation

Benzene
Benzene

PTA
PTA

SULPHUR
SULPHUR

CBFS
CBFS

Butadiene
Butadiene

HDPE
HDPE

LLDPE
LLDPE

MEG
MEG

DEG
DEG

Poly
Poly Propylene
Propylene

POLYOLEFINS

POLY PROPYLENE

POLY ETHYLENE

HOMO

RANDOM

IMPACT

POLYMER

COPOLYMER

COPOLYMER

LDPE

LLDPE

HDPE

Market Scenario - India

Polyolefin Demand/Supply India
7

Cap

Demand

Polyolefin Demand Scenario India

6.1

6
4.8

MMT

5
4

3.8

3.8

3.3

4.2

3.9

3.6

3
2

Effect of current
slowdown

1
0
2007

2008

2009

2010

POSupplyDemand

Supply/DemandMMTPA

4.5

Need To Export from the start

4.0
3.5

PESupply

3.0

PEDemand

2.5

PPSupply

2.0

PPDemand

1.5
2009

2010

2011

2012

AAGR Forecast for Next 5 Yrs

2013

Year
PE

PP

Year

Supply

Demand

Supply

Demand

2009

1.8

2.0

1.9

2010

2.5

2.0

3.6

2.2

2011

2.9

2.7

3.7

2.6

2012

3.7

3.1

3.9

3.1

2013

4.0

3.4

4.2

3.7

PP
LLDPE
HDPE

10.3 %
8.5 %
8.0 %

27

INDIAN PE MANUFACTURES
COMPANY

CAPACITY
KT/YEAR

INDIAN OIL
RIL

650
1050

HPL

550

GAIL
TOTAL

310
2560

INDIAN PP MANUFACTURES
COMPANY

CAPACITY
KT/YEAR

INDIAN OIL
RIL

600
1735

HPL

275

TOTAL

2610

Conventional Design Ethylene Plant

Pyrolysis Heater
S

Gasoline
Fractionator

Fuel Oil
Stripper

Process
Water
Stripper

Quench
Tower

Charge Gas
Compressor
1st - 3rd Stages

ATU,
Caustic &
Water
Wash Tower

Charge Gas
Compressor
4th & 5th
Stages

Condensate
Stripper

W
W

R
W

Fresh Feed

Fuel Oil

Ethylene
Fractionator

Demethanizer Deethanizer

Dryer

Propylene
Fractionator
Methylacetylene &
Propadiene Converter

Depropanizer

Acetylene
Converter

Debutanizer

Fuel Gas

Hydrogen

Methane

Ethane Ethylene

C3 LPG Propylene Gasoline C4 Product

Typical Operating conditions of Naphtha

Cracker
Naphtha cracker constitutes:
Hot section : Heaters
Mid section: Quench Tower
Cold section : Recovery

Operating temperature of heaters : 950 Deg. C

Cold section :
Minimum temperature for methane recovery: - 180 Deg.
Pressure : Around 35 Kg./cm2

Panipat Naphtha Cracker Complex Configuration

Unit

Capacity ( 000 MT/yr)

Naphtha Cracker Unit

857 * ( Ethylene )
650 * ( Propylene)

C4 Hydrogenation Unit

482

Pyrolysis Gasoline Hydrogenation Unit

720

Benzene Extraction Unit

117

Butadiene Extraction Unit

137( to be taken up)

Polypropylene Unit

2x300

LLDPE/HDPE Swing Unit

350

Dedicated HDPE Unit

300

MEG Unit

300

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

NAPHTHA CRACKER UNIT BLOCK FLOW

DIAGRAM
F.G.
DRY
GAS

H2

( from Ref.RFCC)

H2 Expo.
To Refinery

O2

C3 RICH
Stream
(from Ref.PSU)
H
2

ETHYLENE

NAPHATHA
CRACKER

Octene-1

NAPHTH
NAPHTH
A
A

MEG

MEG

H2

PROPYLEN
E

HDPE
LLDPE/HD
PE

DEG
Butene1

HDPE

Butene1

LLDPE
/HDPE

Butene-1

PP

PP
H2

Hydrogen
ated C4

H2

C4HU
Mixed
C-4`s
recycle

C-6 Raff.
recycle

RAW C4 MIX

BUTADIE
NE

BDEU
RAW PY GAS

PGHU
C-5 + C6 recycle

LPG
MIX C4
Recycle

H2

CBFS

C-5 + C-6 Recycle

BZ
PY.

BEU

GASOLIN
E

C-6 Raff.
Recycle

CBFS

C9+
Stream

PROCESS UNITS
UNIT

CAPACITY (MMTPA)

LICENSOR

0.8 (ETHYLENE)

ABB GLOBAL, USA

0.35

NOVA CHEMICALS, USA

POLYPROPYLENE UNIT

0.6

BASELL POLYOLEFINS,
ITALY

HDPE UNIT

0.3

BASELL POLYOLEFINS,
GERMANY

MEG UNIT

0.3

NAPHTHA CRACKER UNIT

LLDPE/HDPE SWING UNIT

SCIENTIFIC DESIGN, USA

MEG Process
All figures are in MT/HR.
C2H4 30.00%
CH4 38.00%
O2 9.00%

0.27

Ar+N2 23.00%

CG purge

Ballast gas
0.0997

C2H4
22.50
O2 23.44

Lean CG
722.34

Cycle
gas
Compr

Reclaim
Compressor

Recycle w ater
340.84
0.905

EO
Reaction
System

Rich CG
767.99

EO Scrubbing
&
CO2 Removal
System

EO
Stripping &
Acid
Scrubbing

Rich CW
989.8
Lean CW
954.29

318.62

EO
Reabsorption
622.14

Glycol
Feed
Stripper

Glycol
383.21

Reaction

CW Bleed
11.70

13.65

CO2 vent

Process steam

DI
Unit

Reflux

Aldehyde

383.21

MP steam

Drying
MEG product MEG

DEG product
TEG product

TEG

DEG

44.37

Refining
Refining

Refining

Evaporation

15.06
Waste w ater 7.34

2.90

0.16

Poly glycol
0.02

49.28
MHP steam

38.14

2.71

0.12

Glycol

Glycol

Purge

waste
Heat
Boiler

MHP steam

MHP steam

MHP steam

0.24

2.49

28.11

MHP steam 57.39

Applications of LDPE & LLDPE

Green House

Bottle Caps

Cable Sheathing

Pouch