Brief Summary of Project Project Name: 1) Acrylics/Oxo Alcohol Project at Dumad near Gujarat Refinery. 2) Creation of necessary facility for origination of Koyali-Ahmednagar-Sholapur Pipeline (KAhPL) & installation of Tank truck loading facility (TTL) for Linear Alkyl Benzene at Dumad near Gujarat Refinery. The project also includes laying of 9 piggable, dedicated hydrocarbon service cross country pipelines (including LPG supply and return) between Refinery and Dumad in the existing Right of Way (ROW). Project Details: 1) Acrylics/Oxo Alcohol Project at Dumad near Gujarat Refinery: a) Background: Butyl Acrylate (acrylate predominantly used in India) has significant growth potential in the Indian Market with its demand expected to grow at ~11% in the next five years. Currently, there is no producer of Butyl Acrylate (BA) in India with the entire domestic requirement (~170 KTA in year 2013) being met through imports. Oxo alcohols are primarily used as inputs for Acrylates production with other small applications like solvents. As part of integrating IOC s Petrochemicals value chain, Indian Oil has planned to manufacture Acrylic Acid/Acrylates and Oxo alcohols near Gujarat Refinery. Based on findings of project configuration evaluation study, the subject project is proposed to be located at IOCL owned land at Dumad next to its Marketing terminal (~ 15 kms away from Gujarat Refinery). Moreover, Western and Northern India being the major demand centers for and proximity to Kandla/Dahej and JNPT, Mumbai ports for accessing the export market, location of the Project at Gujarat will help minimize the logistics cost for product movement. b) Project Configuration: Following project configuration has been considered for the project. Sr. No. New Unit Capacity, KTA 1. Propylene Recovery 120 Unit (PRU) 2. Syn Gas Unit 9300 Nm3/hr + 4850 Nm3/hr of H2 3. Acrylic Acid Unit (AA 90 Unit) 4. n- Butanol Unit 100 5. Butyl Acrylate Unit 153 (BA Unit
A. Raw material - Propylene, 121 KTA B. Intermediate Acrylic Acid production: 90 KTA N-Butanol: 92 KTA (entirely for captive consumption for Butyl Acrylate production) C. Finished Product Butyl Acrylate (BA): 153 KTA Iso-Butanol (IBA): 9 KTA c) Utilities and Offsite: Following product storage facilities have been considered: Product N-butanol I-butanol Acrylic Acid Glacial Acrylic Acid Butyl Acrylate Propylene at Dumad (Note-1) Naphtha (for Syn Gas Unit) Working Capacity (m3) 1025 x 1 tank 232 x 2 tanks 1583 x 1 tank -NA- 3617 x 2 tanks 1410 x 1 bullet 1770 x 2 bullets 468 x 2 tanks A piping corridor already exists between refinery and Dumad marketing terminal. The new pipelines can be routed through the existing piping corridor for which the Right of Way already exists with IOCL. Details of new utility facilities required for Dumad Site are as follows: Item Demand Remarks Power(MW) 17 A petcoke based captive power plant (CPP) of Steam (TPH) 17 MW power and 200 T/hr steam production HP 90 Tons/hr capacity (One 200 TPH CFBC boiler and one MP 10 Tons/hr 17 MW STG with grid power backup) has been LP 49 Tons/hr envisaged. Cooling Water 16320 Instrument air (Nm3/hr): Plant air: (Nm3/hr) Nitrogen (Nm3/hr) Raw Water 1700 350 Cooling water system of 16800 m3/hr capacity (5*4200 m3/hr cells, 4 working + 1 Standby) with associated facilities will be provided. New plant and instrument air system envisaged. 800 New unit of 900 Nm3/hr N2 generation capacity envisaged. 400 To be sourced from existing IOCL jack wells in Mahi river (through new pipeline, pump and
associated facilities). Fire Water 1700 New system comprising of fire water storage, fire water pumps and distribution piping network considered for fighting two fires simultaneously. Flare (Nm3/hr) 81000 (equivalent to 11 TPH) New flare system envisaged. Capacity will be assessed during DFR stage Effluent (T/hr) 130 New Zero Liquid Discharge (ZLD) ETP of 155 T/hr capacity envisaged. Final sludge after treatment in ZLD plant can be either sent to incinerator or for land-filling. d) Project Cost: Rs. 4157 crores. 2) Koyali-Ahmednagar-Sholapur Pipeline (KAhPL) & Tank truck loading facility for Linear Alkyl Benzene at Dumad, near Gujarat Refinery: a) Background: Indian Oil Corporation Limited is planning to lay a new Koyali- Ahmednagar Sholapur pipeline, that can feed products from Gujarat Refinery to more economically linked locations in Maharashtra and Karnataka, which are otherwise dependent on exchanges with other OMCs or rail input from distant sources for product supply. Board approval for the project has also been obtained and it has been decided that necessary infrastructure/facilties shall be constructed at Dumad along with necessary modification at Gujarat Refinery for origination of KAhPL from Dumad. Similarly, Gujarat Refinery is also planning to shift Tank Truck Lorry (TTL) loading facility of Low Molecular Weight (LMW) and High Molecular Weight (HMW) Linear Alkyl Benzene (LAB) product to Dumad area as the existing TTL gantry is unsafe. There is no scope for shifting the Tank Truck (TT) gantry to alternate location in the refinery with existing loading volumes. Excluding Low Molecular Weight (LMW) and High Molecular Weight (HMW), other specialty products loading facility can be shifted to alternate location within refinery due to lower number of TT s involved. In addition to the above, TTL shifting would also lead to decongestion and enhanced safety aspects of JR along with sparing of 5 acres of land approximately which can be utilized for future projects. b) Project Configuration: No new manufacturing/production units are envisaged in this project. Only construction of additional tanks, pipelines as well as installation of pumps envisaged both at Gujarat Refinery as well as project site (Dumad).
i) Facilities envisaged at Gujarat Refinery end: Additional PLT pumps in existing pump house at Refinery along with necessary suction piping from product tanks like MS/HSD/SKO/ATF/LMW/HMW. Necessary electrical facilities for the new pumps like substation, feeder panel, cables, transformer, Pig launching barrel & receiving barrel provision for above dedicated products lines located at extreme north end of refinery & ISBL of Dumad respectively. 9 Piggable cross country Koyali-Dumad dedicated product pipeline are to be installed in existing ROW for transfer of products to proposed Dumad tanks. ii) Facilities envisaged at Dumad end: Installation of additional product tanks as well as utility tanks. Details have been mentioned below: Sr No Description Capacity Nos. 1 HSD Tanks 30,000kl 4 2 MS Tanks 20,000kl 3 3 ATF Tanks 10,000kl 3 4 PCK Tanks 10,000kl 2 5 SKO Tanks 5,000kl 2 6 Fire Water Tanks 6,000kl 3 7 Service Water Tanks 6,000kl 1 8 LMW 15000kl 3 9 HMW 5000kl 1 Additional pumps for Fire Water, Service water, booster pumps, TT loading dedicated pumps along with circulation system for LMW and HMW. Necessary pipings from the new tanks. TTL loading bays (5 bays with dual loading) along with all necessary associated instrumentation facilities for custody transfer metering and invoicing system. Fire water network, hydrant, HVLR, fire tender, gas and smoke detector system in control rooms and associated safety items. Fire protection facilities for TT Loading gantry. c) Utilities: Details of new utility facilities required for Dumad Site are as follows
Item Power Raw Water Fire Water Effluent (T/hr) Facilities envisaged Power requirement: 6 MW. No new facility for power generation considered in project. Existing refinery captive power generation facilities will be sufficient for supplying the same. Existing underground 33 KV dual lines may be sufficient, which were laid from Gujarat Refinery to Dumad Approx. 40 m3/hr of raw water from Bore well. Details of new fire water tanks have already been mentioned under Project Configuration. New ETP of design capacity 120 m3/hr has been envisaged to treat hydrocarbon generated during Maintenance & Inspection. d) Project Cost: Necessary facility for origination of Koyali-Ahmednagar-Sholapur Pipeline (KAhPL): Rs 707 crores. TTL shifting: Rs. 142.45 crores.