PREFEASIBILITY REPORT FOR “REVAMP OF DIESEL HYDRO DE – SULPHURISATION UNIT” BY CHENNAI PETROLEUM CORPORATION LIMITED AT VILLAGE: MANALI TALUK: AMBATTUR DISTRICT: THIRVALLUR STATE: TAMIL NADU Prepared by HUBERT ENVIRO CARE SYSTEMS PRIVATE LIMITED DECEMBER 2015 1 TABLE OF CONTENTS 1. EXECUTIVE SUMMARY............................................................................................................. 5 2. INTRODUCTION OF THE PROJECT .......................................................................................... 6 2.1 ABOUT THE PROJECT PROPONENT ................................................................................ 6 2.2 MAJOR PRODUCTS OF CPCL ............................................................................................ 6 2.3 ABOUT THE PROJECT ........................................................................................................ 7 2.4 PROJECT BENEFITS ............................................................................................................ 8 3. PROJECT DESCRIPTION ............................................................................................................. 9 3.1 TYPE OF PROJECT ............................................................................................................... 9 3.2 PROJECT LOCATION .......................................................................................................... 9 3.3 MAJOR PROJECTS OF CPCL ............................................................................................ 10 3.4 DESCRIPTION OF THE PROJECT .................................................................................... 11 3.5 PROJECT NEED .................................................................................................................. 11 3.6 MANUFACTURING PROCESS DESCRIPTION .............................................................. 12 3.6.1 REACTION SECTION ..................................................................................................... 12 3.6.1.1 FIRST HDS REACTOR 77-C102 .................................................................................... 16 3.6.1.2 SECOND HDS REACTOR 77-C3 ................................................................................... 16 3.6.2 CATALYST INVENTORY ............................................................................................. 18 3.6.3 STRIPPING AND STABILIZING SECTION ................................................................. 20 3.6.4 DRYER SECTION ........................................................................................................... 27 3.6.5 POWER AND FUELS ...................................................................................................... 30 3.6.6 LAND USE ....................................................................................................................... 30 3.6.7 MANPOWER ................................................................................................................... 30 3.6.8 WATER REQUIREMENT ............................................................................................... 31 3.6.9 UTILITIES ........................................................................................................................ 31 3.7 LIQUID WASTE MANAGEMENT .................................................................................... 32 3.7.1 DURING NORMAL OPERATION ................................................................................. 32 3.7.2 DURING START – UP .................................................................................................... 33 3.7.3 DURING SHUT-DOWN .................................................................................................. 33 3.8 AIR POLLUTION CONTROL MEASURES ...................................................................... 33 3.9 HAZARDOUS AND SOLID WASTE MANAGEMENT ................................................... 34 3.10 GREEN BELT DEVELOPMENT ........................................................................................ 35 3.11 ENVIRONMENT, SAFETY AND HEALTH MONITORING ........................................... 35 4. SITE ANALYSIS ......................................................................................................................... 37 4.1 CONNECTIVITY ................................................................................................................. 37 2 4.2 LAND FORM, LAND USE, LAND OWNERSHIP ............................................................ 37 4.3 EXISTING LAND USE PATTERN ..................................................................................... 37 4.4 CLIMATIC CONDITIONS .................................................................................................. 37 5. CONCLUSION ............................................................................................................................. 39 LIST OF TABLES Table 2.1 BS IV Specifications for Diesel ................................................................................. 7 Table 2.2 BS V Specifications for diesel ................................................................................... 8 Table 3.1 Capacity of major units of CPCL ............................................................................ 11 Table 3.2 BS Specifications ..................................................................................................... 12 Table 3.3 Specifications of Diesel and VGO Case .................................................................. 13 Table 3.4 Catalyst Details ........................................................................................................ 16 Table 3.5 Catalyst loading details of Second HDS Reactor .................................................... 16 Table 3.6 Catalyst Inventory details ........................................................................................ 19 Table 3.7 Power and fuel requirement ..................................................................................... 30 Table 3.8 List of Utilities ......................................................................................................... 31 Table 3.9 Liquid Effluent details ............................................................................................. 32 Table 3.10 Waste water details during DHDS Catalyst Presulphiding ................................... 33 Table 3.11 Waste water details of Reactor Heater Decoking .................................................. 33 Table 3.12 Air pollution emissions .......................................................................................... 33 Table 3.13 Municipal Solid Waste details ............................................................................... 34 Table 4.1 Water bodies in the study area ................................................................................. 37 Table 4.2 Meteorological Observations ................................................................................... 38 LIST OF FIGURES Figure 3.1 Project Site................................................................................................................ 9 Figure 3.2 10 km Radius around project site ........................................................................... 10 Figure 3.3 Reaction Section for Diesel Case ........................................................................... 14 Figure 3.4 Reaction Section for VGO Case ............................................................................. 15 Figure 3.5 Reactor (77 – C102) Loading diagram ................................................................... 17 Figure 3.6 Reactor (77 – C3) loading ...................................................................................... 18 Figure 3.7 Stripping Section Diesel Case ................................................................................ 22 Figure 3.8 Stripping Section VGO Case .................................................................................. 23 Figure 3.9 Stablilisation Section Diesel Case .......................................................................... 24 Figure 3.10 Stabilisation Section VGO Case ........................................................................... 25 Figure 3.11 Dryer Section Diesel Case .................................................................................... 28 Figure 3.12 Dryer Section for VGO Case ................................................................................ 29 3 LIST OF ABBREVIATIONS BS Bharath Stage CBR Cauvery Basin Refinery CDU Crude Distillation Unit CPCL Chennai Petroleum Corporation Limited CRU Catalytic Reforming Unit DCU Delayed Coker Unit DHDS Diesel Hydro De-Sulphurisation DHDT Diesel Hydro Treating EOR End of Run FCCU Fluidized Catalytic Cracking Unit HCO Heavy Cycle Oil ISOM Isomerisation Unit LABFS Linear Alkyl Benzene Feed Stock LCO Light Cycle Oil LOBS Heavy Cycle Oil LPG Lube Oil Base Stock LVGO Liquefied Petroleum Gas MDEA Light Vacuum Gas Oil MEK Methyl Di-Ethanol Amine MMT Methyl Ethyl Ketone MMTPA Million Metric Tonnes MP Million Metric Tonnes Per Annum OHCU Medium Pressure SOR Once-through Hydro Cracker Unit SRGO Start of Run SRU Straight Run Gas Oil VBU Sulphur Recovery Unit VGO Visbreaker Unit 4 1. EXECUTIVE SUMMARY Chennai Petroleum Corporation Limited (CPCL) is the oldest refinery in Southern part of India and the most complex public sector refinery within India in a spread of 800 acres land.