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1 Brief Summary of Proposed Project INTRODUCTION GAIL (India) Brief Summary of Proposed Project INTRODUCTION GAIL (India) Limited (‘GAIL’) along with Hindustan Petroleum Corporation Limited (‘HPCL’) is exploring the opportunity for setting up a Greenfield Petrochemical Complex in Andhra Pradesh to produce 1 MMTPA of ethylene and ethylene derivatives based on imported ethane and / or Naphtha available in domestic market. Project Location The proposed Petrochemical complex will be located at A.V. Nagaram village, Thondangi Mandal of East Godavari district, Andhra Pradesh. The proposed complex is spread across 2000 acres. Nearest airport is Rajahmundry (87 km) from proposed site. Power source 33KV /132 KV Power source from AP Transmission Corporation at Pithapuram substation is available near the site at a distance of about 25 Km. Construction and Permanent water source Site has proximity with the source of water. Polavarum left main Canal (AP irrigation) is approximately 12 KM from the proposed site, Samalkot is an alternate source of water which is around 28 KM from the proposed site. Environmental requirements No Ecologically sensitive area like national monument / bird sanctuaries/ major settlement is located within 25 Km of site. Defence requirements No Defence base within 25 Km of the site. Downstream Industry No downstream industry related to Petrochemical in the vicinity. Topography of site & development requirement: The topography of the proposed area is flat terrain with minor sand dune hillocks which includes one major Creek running across the proposed site. Project Description The process facilities with capacities are described in Table 1. Table 1: Process Unit Capacities Sr.no. Process Units Capacity, KTPA 1. Cracker Unit 1000 2. C4/C5 Hydrogenation unit 390 3. Pyrolysis Gasoline Hydrogenation Unit 320 4. Benzene Extraction Unit 70 1 5. Mono-Ethylene Glycol(MEG) Unit 700 6. LLDPE / HDPE 450 7. Butene-1 25 8. Chloro Alkali 177 (Chlorine Basis) 9. VCM 300 10. PVC 300 11. Poly-Propylene Unit 315 Utilities Description Facilities in utility systems are enlisted below: Cooling water system Steam, Power and boiler feed water system Treated Raw water system DM Water plant Condensate polishing system N2O2 (Nitrogen/Oxygen) Plant Instrument Air & Plant Air system Effluent treatment Plant Flare system Cooling Water Requirement for the Complex is about 125000 M3/Hr. To carter to the requirement cooling towers with cell capacity of 4000 M3/Hr each. In order to meet the steam, power and boiler feed water demands of the facilities installed at the Petrochemical complex, dedicated steam, power and BFW system will be installed as part of the Captive Power Plant (CPP). Raw Water Requirement Raw Water requirement is 3900 m3/hr. Water will be sourced from Polavaram Canal which is 12 kms from the Complex. Raw water shall be made available at complex battery limit from canal via Raw Water Pumping facility. To meet the complex demand one raw water reservoir of 2100000 m3 capacities is considered. This reservoir is designed to cater the 21 days of raw water demand. DM Water/Oxygen/Instrument & Plant Air Requirement The normal requirement of DM water is about 210 M3/Hr of DM water and 590 M3/Hr of net raw water generation. The requirement of Oxygen is 1450 TPD (Design) and that of Nitrogen is Normal – 12776 NM3/Hr and Max – 20000 NM3/Hr. Oxygen is required in MEG unit as a raw material. The design requirement of Instrument air and plant air is about 6000 NM3/Hr and 5500 NM3/Hr respectively. Effluent Treatment Plant The Effluent treatment plant is shall take care the following effluent quantity. Oily Effluent 250 M3/Hr. 2 Wet air oxidation unit to treat spent Caustic of about 2 M3/Hr Various Effluents generated from the complex shall be treated in a centralized ETP. The various effluents sent to the ETP broadly consist of the following: Oily Water Sewerage Contaminated Rain Water Sewerage Spent Caustic Stream Sanitary Effluent Flare System A centralized demountable flare system is proposed for the facility. A Demountable flare system provides flexible flaring operations to so that you can place multiple risers on a single support structure. They also allow you to perform maintenance to the tip at grade with minimal use of personnel at elevation. 3 Risers are presently envisaged in the flare: Flare gas from Cracker Flare gas from polymer units Flare gas from storage facilities Offsite Description Offsite facilities will include storage vessels / tanks / sphere for feed, intermediates feed, Off spec intermediate feed & products, pumping facilities, loading / unloading facilities and auxiliary facilities like boil off gas compression system, emergency vaporization / heating system / vapor recovery system etc. Offsite storage summary is given in Table 2. Table 2: Offsite Storage Summary Service Phase Capacity / Type of Location Basis of capacity Nos. storage 3 Ethane Liquid 100000 M DWST At the 2 Ship Parcel of x 2 Nos. KSPL port 87000 M3 each. Which will carter to about 28 days of Cracker Operation Propane Liquid 35000 M3 x DWST At the 2 Ship Parcel of 2 Nos. KSPL port 30000 M3 each. Which will carter to about 41 days of Cracker Operation. Ethane Liquid 1900 M3 x 2 Sphere In 1 Day Buffer Nos. Complex 3 Propane Liquid 900 M3 x 2 Bullet In 1 Day Buffer Nos. Complex Naphtha Liquid 16500 M3 x Internal In 7 days 2 Nos. Floating Complex roof tank Hexene-1 Liquid 1700 M3 x Cone roof In 1 No. Nitrogen Complex Blanketing Tank Table 2: Offsite Storage Summary Service Phase Capacity / Type of Location Basis of capacity Nos. storage Pentane Liquid 250 M3 x 1 Bullet In 30 days No. Complex Hexane Liquid 500 M3 x 1 Internal In 30 days No. Floating Complex roof tank Salt Solid 15 KTPA Open CA Unit 15 Days Storage Intermediate Ethylene Liquid 24000 M3 x DWST In 7 days Complex 2 Nos. Propylene Liquid 3250 M3 x Bullet In 7 days Complex 5 Nos. Butene-1 Liguid 1517 M3 x Mounded In 7 Days Complex 1 No. Bullet C4 Mix Liquid 2500 M3 x Sphere In 3 days Complex 2 Nos. Offspec Liquid 1700 M3 x Sphere In 12 Hrs Complex C4 Mix 1 No. C6 Cut Liquid 1700 M3 x Internal In 3 days Complex (BzeU 2 Nos. Floating feed) roof tank 4 Off spec Liquid 1767 M3 x Sphere In 12 hrs. with 100% Complex plant capacity Ethylene 2 Nos. Off spec Liquid 1785 / M3 x Mounded In 12 hrs. with 100% Complex Propylene 1 No. Bullet plant capacity Hydrogen Gas 50 M3 x 2 Above In 7 Days Complex Nos. Ground Bullet Table 2: Offsite Storage Summary Service Phase Capacity / Type of Location Basis of capacity Nos. storage RPG Liquid 2174 M3 x Dome In 3 Days Complex 2 Nos. roof tank EDC Liquid 3780 M3 x Internal In Complex 3 Nos. Floating roof tank VCM Liquid 3804 M3 x Spheres In 7 Days 2 Nos. Complex Products MEG Liquid 17100 M3 x Fixed roof In 15 days Complex 2 Nos. tank DEG Liquid 2500 M3 x Fixed roof In 15 days Complex 1 No. tank TEG Liquid 150 M3 x 1 Fixed roof In 15 days Complex No. tank HPG Liquid 3000 M3 x Internal In 15 Days Complex 2 Nos. Floating roof tank PGO Liquid 1000 M3 x Cone roof In 15 Days 2 Nos. Complex Nitrogen Blanketing Tank PFO / Liquid 700 M3 x 2 Fixed roof In 15 Days Nos. Complex CBFS Tank 5 Benzene Liquid 2000 M3 x Internal In 15 Days Complex 2 Nos. Floating roof tank Table 2: Offsite Storage Summary Service Phase Capacity / Type of Location Basis of capacity Nos. storage C6+ Liquid 300 M3 x 1 Internal In 15 Days Complex Oligomer Nos. Floating roof tank Slop Liquid 1700 M3 x Internal In From ETP. Complex 1 No. Floating roof tank Caustic for Liquid / 18 KT Warehouse In Part of CA ISBL. 30 Complex sales Solid and Tanks Days PVC Solid 27 KT PWH In 30 days. Complex Poly Solid 28.4 KT PWH In 30 days. Complex Propylene HDPE/ solid 40.5 KT PWH In 30 days. Complex LLDPE Supply of Ethane Based on the requirement of the parcel size of Ethane import through VLEC (Each having ~ 87000 M3 capacity) has been considered as basis for the storage and the capacity has been fixed to 100000 M3. The option selected for the proposed complex is tabulated below: Unloading and storage at port. Heating and transportation through non-cryogenic pipeline up to Petrochemical Complex. VLEC carrier would can be berthed at a jetty near the breakwater of KSPL port. Length of trestle required is 1.75 km for laying the cryogenic lines from DWST to Jetty. The jetty location is proposed adjacent to proposed LNG Jetty at KSPL port. 6 Supply of Propane Based on the requirement of the parcel size of Propane import through vessel of capacity of about 30000 M3 has been considered. Based on vessel capacity the storage and the capacity has been fixed to 35000 M3. Supply of Naphtha The Major Facilities are envisaged for transportation of Naphtha: 1+1 Nos pf Booster Pump and 1+1 Nos of Mainline Pump of 200 M3/Hr each will be installed in the premises of HPCL refinery. 12” Naphtha Pipeline with length of 150 Kms. Pig Launcher and Receiver Flow Meters (Both at Dispatch and Receipt facility for custody transfer) Surge Relief Valve (At Receipt facility) Corrosion Inhibitor dosing facility (At Dispatch facility) Marine Discharge of Treated Effluent The treated effluent is proposed to be disposed in sea via pipeline of total Length 7 Kms which includes 6 Kms Onshore with 500 M Buried Portion and 1 Km Inside the sea. Receipt of Salt Salt would be received by Road.
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