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Annexure-I Product Pattern After Implementation of Projects Sl No Annexure-I Product Pattern after Implementation of Projects Sl No Project Case (A) Crude 1 Assam 320 2 Imported 2,380 3 Total 2,700 (B) Products 1 LPG 249 2 Naphtha 26 3 MS 529 4 SKO 136 5 HSD 1,407 6 LDO 45 7 FO - 8 RPC 40 Annexure-II Fresh Water Requirement Sl Particulars Source Requirement Remarks No. (m3/hr) (1) Raw water for - - No additional raw water CDU-II, required DHDT, SDS & CRU-MSQ (2) Raw water for Ground water 50 Treated effluent water from INDMAX TTP will be reused in Cooling Tower make-up. Raw water requirement is for Service Water and Drinking Water only. Annexure-III Utilities Requirement (Steam, Power & Fuel) Sl Particulars Unit CDU-II DHDT CRU- INDMAX IGHDS SDS Total No. MSQ FCC Unit Unit Unit (1) Steam MT/hr No - Net SL Steam No No No 4.5 - change 4.5 - Net MP Steam change change change 34.4 8.8 43.2 - Net HP Steam (0.3) - (0.3) (2) Power KW - 300 - 3,620 255 45 4,220 (3) Fuel (Fuel Gas) MMKcal/hr 0.63 0.44 0.17 - 0.9 - 0.9 Note: There is no direct fuel requirement in INDMAX Unit and SDS Unit Annexure-IV Stack Emissions Sl Stack Emissions (kg/hr) No. SOx NOx (1) INDMAX FCC Regenerator 43.6 16.1 (2) IGHDS Unit 0.04 0.16 (3) CDU-II 6.86 0.55 (4) DHDT 0.03 0.39 (5) CRU 0.01 0.15 (6) MSQ - - (7) SDS Unit - - Annexure-V Liquid Effluent Generation Sl Particulars Unit Quantity Remarks No. (1) Liquid effluent m3/hr - No additional liquid effluent will from CDU-II, be generated DHDT, SDS & CRU-MSQ (2) Liquid Effluent m3/hr 28.0 Liquid effluent generation from from INDMAX INDMAX FCC Unit only. No continuous liquid effluent generation from IGHDS Unit. Note: The liquid effluent from the Indmax Unit will be treated in the existing Waste Water Treatment Plant. The treated effluent will be reused as Cooling Tower make-up. Annexure-VI Solid Waste Generation Sl Particulars Quantity Remarks Disposal No. (1) DHDT 31 MT Catalyst Replacement once in Disposal to CPCB catalyst (for 5 years) 5 years registered recyclers (2) CRU catalyst 9 MT catalyst Replacement once in Disposal to CPCB (for 5 years) 5 years registered recyclers Platinum will be recovered (3) MSQ catalyst 27 MT Catalyst Replacement once in Disposal to CPCB (For 5 years) 10 years registered recyclers Platinum will be recovered (4) INDMAX FCC 600 MTPA Continuous Disposal to CPCB Catalyst Catalyst regeneration of registered recyclers catalyst – make-up rate is 1.8 TPD (5) HDS Catalyst 9 MT Catalyst Replacement once in Disposal to CPCB (For 6 Years) 6 years registered recyclers (6) SDS Catalyst 3 MT Catalyst Replacement once in Disposal to CPCB (For 5 Years) 5 years registered recyclers Note: Except spent catalysts, there is no other solid waste generation during operation of the INDMAX project. Annexure-VII MANUFACTURING PROCESS DETAILS (A) Crude Capacity Enhancement: Presently crude processing capacity of Bongaigaon Refinery is 2.35 MMTPA having two Crude Distillation Units(CDU) CDU-I having nameplate capacity of 1.35 MMTPA CDU-II having nameplate capacity of 1.00 MMTPA After OIL crude pipeline HBCPL capacity enhancement from 7.5 to 9.2 MMTPA, crude availability to BGR will be 2.7 MMTPA. This project is expected by August 2015. Presently the CDU-II unit is capable to process crude of 1.35 MMTPA against its nameplate capacity of 1.0 MMTPA. To enhance BGR crude processing capacity to 2.7 MMTPA, it is proposed to increase the nameplate capacity of CDU-II unit from 1.0 MMTPA to 1.35 MMPTA. No additional facility is required for this project. (B) DHDT Capacity Enhancement to meet BS-V/VI HSD specification: The DHDT unit of BGR is designed to process 1,200 TMTPA of HDT feed with balance 25- 30 % directly back blended to HSD. The diesel produced ex-DHDT unit meets BS-V specification, specially the stringent sulfur specification of 10 ppm. However, in BS-IV & BS-V regime, the total quantity of HSD feed streams will have to be processed via DHDT unit to meet the sulfur and Cetane specification of BS-V HSD. In order to sustain HSD production at the existing level under BS-IV /V scenario, the capacity of the DHDT plant is required to be increased to 150% of the existing capacity i.e. to 1,800 TMTPA from the existing level of 1,200 TMTPA to process all available diesel feed streams. In order to have clarity the HSD specifications for BS-III, BS-V & BS-V HSD is tabulated below: Specifications for Diesel SL Attribute Unit BS-III BS-IV BS-V No. 1 Density @15°C kg/m3, max 820-845 820-845 820–845 2 Distillation T95 °C max 360 360 360 3 Sulphur ppm max 350 50 10 4 Cetane No min. 51 51 51 5 Cetane Index min. 46 46 46 Specifications for Diesel SL Attribute Unit BS-III BS-IV BS-V No. 6 Flash Point °C min. 35 35 42 7 Viscosity @ 40°C cSt 2.0−4.5 2.0−4.5 2.0–4.5 8 PAH % wt. max 11 11 11 9 Total Contaminants mg/kg max 24 24 24 10 RCR on 10% Residue % wt. max 0.3 0.3 0.3 11 Water Content mg/kg max 200 200 200 Lubricity, Corrected 12 Wear Scar Diameter Microns, max 460 460 460 (WSD) @ 60°C 13 Ash % wt. max 0.01 0.01 0.01 14 Cold Filter Plugging Point 14a Summer, max °C 18 18 18 14b Winter, max °C 6 6 6 15 Oxidation stability g/m3, max 25 25 25 Copper strip corrosion 16 Rating Class 1 Class 1 Class 1 for 3 hrs @ 50°C, max (C) CRU-MSQ Revamp to meet BS-V/VI HSD specification: In order to meet the aromatic limit of 35 vol% in MS , the Light Naphtha ISOM unit will have to be revamped with a new catalyst along with re-orientation of process configuration to produce Isomerate of RON 90 from the present level of 85. Possibility of RON improvement by changing the catalyst from present zeolite based catalyst to Sulfated Zirconia based catalyst has been discussed with Licensors. Further to meet Sulfur level of < 10 ppm in BS-V MS a new Naphtha Hydrotreater will have to be installed for hydrodesulphurization of the straight run naphtha . A detailed study of the Light Naphtha Isom unit s required to be carried out for identifying the modifications and for preparation of the feasibility report. In order to absorb all the naptha into MS, the capacity revamp of the CRU unit is required to be increased from the present 160 TMTPA to around 200 TMTPA. Further, BGR is exploring the option of revamping the existing Isomerisation unit with an additional reactor for improving Isomerate RON from present 84-85 to 90 -91 for which, M/s GTC Technologies is being consulted for putting up an additional reactor with Sulfated Zirconia based catalyst. (D) Selective Desulphurisation Unit (SDS): SDS is a trickle bed reactor system with single stage once through down flow configuration. The hydrogen consumption is very low and the reduction in sulfur is very negligible. The SDS reactor is filled with proprietary catalyst developed by IOC R&D and the conventional guard bed at the top sufficient enough to handle silica rich Coker streams. The key functionality of the catalyst is to selectively saturate the diolefins and shift low molecular weight sulfur compounds to high molecular weight sulfur compounds. These diolefins are selectively removed under very mild conditions of hydrotreating in SDS Reactor. Sulfur Shift mechanism, the low boiling sulfur compounds are converted to high boiling sulfur compounds by combination of low boiling sulfur compounds with olefins. Due to this reaction, it is possible to segregate the light boiling range gasoline from full range gasoline by distillation before hydrodesulfurization, since all of its sulfur are shifted to high boiling region. The diolefins treated & sulfur shifted stream is separated in to light & heavy cut through a conventional splitter. The lighter cut which is olefins rich (octane potential) & low sulfur stream is taken to gasoline pool for blending without any post treatment. In this stream, the sulfur content is low due to the sulfur shift mechanism, all low boiling sulfur compounds are ended up in the heavy cut. (E) INDMAX Unit along with Indmax Gasoline De-Sulphurisation Unit: (E.1) INDMAX Unit Presently, Coker Naphtha and Coker Gas Oil & Coker Fuel Oil from Delayed Coker Unit are being blended and evacuated as BS-II Motor Spirit (MS) and LDO & LVFO respectively. With the implementation of Euro-III equivalent fuel norms effective from 2010, it will not be possible to blend Coker Naphtha in the MS pool and will surplus as Naphtha. Also, increasing availability and demand of Natural Gas, the demand of Naphtha and LDO/LVFO (Black Oil) are decreasing day by day. In view of the above, BGR is implementing INDMAX Unit of 740 TMT per annum capacity at BGR to process Coker Naphtha, Coker Heavy Gasoil (CHGO), Reduced Black Oil (RCO) and Black Oil components and thereby to increase value added products LPG and MS. The feed to the INDMAX Unit of BGR comprises of Coker Naphtha (CN), Coker Heavy Gasoil (CHGO) and Coker Fuel Oil (CFO) from Delayed Coker units & Reduced Crude Oil (RCO) ex Crude Distillation units. INDMAX is proprietary process developed and patented by IOCL (R&D) similar to Residue Fluid Catalytic Cracking (RFCC) process except that the catalyst system and operating conditions are different.
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