PROJECT PRE-FEASIBILITY

REPORT

for

Proposed Expansion Projects

at

Jamnagar Manufacturing Division

V 18/10/2019

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CONTENTS

1. INTRODUCTION ................................................................................................................ 4
1.1. Need for the Proposed Projects. ................................................................................. 5
1.1.1. Multi-Feed Steam Cracker (MFSC) ......................................................................... 6
1.1.2. Multi-zone catalytic cracking (MCC): ....................................................................... 6
1.1.3. C1 complex ............................................................................................................. 6
1.1.4. C2 complex ............................................................................................................. 6
1.1.5. C3 complex ............................................................................................................. 6
1.1.6. C4 complex ............................................................................................................. 7
1.1.7. Aromatics complex .................................................................................................. 7
1.2. Proposed Land Use .................................................................................................... 7
1.3. Project Setting ............................................................................................................ 7
1.4. Locational Advantages ............................................................................................... 9
1.5. Proposed Projects ...................................................................................................... 9
1.6. Need for Environmental Clearance: Categorization of the Project .............................. 9
1.7. Capital Cost of the Project ........................................................................................ 10

2. PROJECT DESCRIPTION ............................................................................................... 13

2.1. PetroFCC ................................................................................................................. 13
2.2. MCC ......................................................................................................................... 14
2.3. ROG Cracker............................................................................................................ 14
2.4. Multi feed steam cracker (MFSC) ............................................................................. 14
2.5. C2= + C3= recovery................................................................................................... 14
2.6. BTX+ extraction ........................................................................................................ 15
2.7. Toluene methylation ................................................................................................. 15
2.8. Trans-alkylation ........................................................................................................ 15
2.9. Paraxylene (PX) ....................................................................................................... 16
2.10. Butadiene extraction .............................................................................................. 16
2.11. High Severity Reformer ......................................................................................... 16
2.12. C1 based Units ...................................................................................................... 16
2.12.1. Acetic Acid ............................................................................................................ 16
2.12.2. Acetic Anhydride ................................................................................................... 17
2.12.3. Ethyl Acetate ......................................................................................................... 17
2.12.4. Vinyl Acetate Monomer (VAM) .............................................................................. 17
2.12.5. Vinyl Acetate Ethylene (VAE) ................................................................................ 17
2.12.6. Ethylene Vinyl Acetate (EVA) ................................................................................ 17
2.12.7. Polyvinyl Acetate ................................................................................................... 17
2.12.8. Polyvinyl Alcohol ................................................................................................... 18
2.12.9. Formic acid............................................................................................................ 18
2.12.10. Di Methyl Ether (DME)........................................................................................... 18
2.12.11. Poly-ketones ......................................................................................................... 18
2.12.12. Isononyl Alcohol (INA) ........................................................................................... 18
2.12.13. Methyl Methacrylate (MMA) ................................................................................... 18
2.12.14. Polymethyl Methacrylate (PMMA) ......................................................................... 19
2.12.15. Rare gases ............................................................................................................ 19
2.12.16. Methanol ............................................................................................................... 19
2.12.17. Ethanol .................................................................................................................. 19
2.12.18. Ammonia (NH3) ..................................................................................................... 20
2.12.19. Urea ...................................................................................................................... 20
2.13. C2 Based Units ...................................................................................................... 20
2.13.1. Vinyl Chloride Monomer (VCM) ............................................................................. 20
2.13.2. Poly Vinyl Chloride(PVC) ....................................................................................... 20
2.13.3. Ethylene Glycol (EG) ............................................................................................. 20
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2.13.4. Poly Ethylene (PE) ................................................................................................ 21
2.13.5. Ethylene Propylene Diene Monomer (EPDM) ........................................................ 21
2.14. C3 Based Units ...................................................................................................... 21
2.14.1. Acrylic acid ............................................................................................................ 21
2.14.2. Glacial acrylic acid................................................................................................. 22
2.14.3. Oxo-alcohols ......................................................................................................... 22
2.14.4. Acrylates ............................................................................................................... 22
2.14.5. Iso-propyl Alcohol (IPA) ......................................................................................... 23
2.14.6. Propylene Oxide (PO) ........................................................................................... 23
2.14.7. Polyols / Propylene Glycol (PG) ............................................................................ 24
2.14.8. Polypropylene (PP) ............................................................................................... 24
2.15. C4 Based Units ...................................................................................................... 24
2.15.1. PBR....................................................................................................................... 24
2.15.2. S-SBR ................................................................................................................... 24
2.16. C6 + Units .............................................................................................................. 25
2.16.1. Styrene / Polystyrene ............................................................................................ 25
2.16.2. Carbon Black (CB) ................................................................................................ 25
2.16.3. Poly-phenylene Sulfide (PPS) ............................................................................... 25
2.17. PDH ...................................................................................................................... 25
2.18. Petcoke Gasification: ............................................................................................. 26
2.19. Battery Manufacture and Metals recovery ............................................................. 26
2.20. Captive Co-generation Gas/Liquid Based Power Plant .......................................... 27

3.0 ENVIRONMENTAL ASPECTS......................................................................................... 28

3.1 Air Emissions ...................................................................................................... 29
3.2 Water Requirement and Wastewater Generation ..................................................... 29
3.2.1 Water Requirement ............................................................................................... 29
3.2.2 Waste Water Generation ....................................................................................... 29
3.3 Solid / Hazardous Waste Generation ................................................................... 30
3.4 Biological Environment ......................................................................................... 30
3.5 Socio Economic Environment ................................................................................... 30

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Chapter 1
Introduction
1. Introduction
M/s Reliance Industries Limited (RIL) operates an integrated petroleum refinery +
petrochemical complex, referred to as the Jamnagar supersite, which includes
associated utilities, offsites and infrastructure facilities, at Motikhavdi village, in the
Jamnagar district of Gujarat. India.
The Jamnagar supersite represents a prime example of a cluster development,
comprising of the following interlinked clusters:
• DTA or domestic tariff area refinery
• SEZ or special economic zone refinery
• Petrochemical complex
• Gasification complex
• Utilities, offsites and infrastructure facilities
The Jamnagar supersite refines crude oil to produce petroleum products and
petrochemical feedstocks + products.
Utilities for the Jamnagar supersite include seawater intake and outfall facilities,
seawater storage and treatment facilities, integrated desalination and effluent
treatment plants. Utilities also include captive co-generation power plant to supply
100% power and steam to the Jamnagar supersite.
Offsites for the Jamnagar supersite include a marine tank farm to logistically support
crude receipt + product shipping; refinery tank farm to seamlessly support the
supersite operations; and rail/road tank farm + warehouses to support efficient
storage + dispatch of refinery products.
The infrastructure facilities, to support the Jamnagar supersite, include deep water
Single Point Moorings (SPMs) for the receipt of crude oil + export of petroleum
products and associated pipelines; liquid jetties + shipping berths, and associated
pipelines + approaches to the jetties for dispatch of products; RO-RO jetty + LO-LO

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jetty for handling project cargoes; on-shore terminals for storage of crude + products
and rail + road loading and unloading bays.
Jamnagar is connected to the cross-country pipelines for inland LPG distribution +
regasified LNG receipt.
The existing Environmental Clearance (EC) for the crude refining capacity of the
Jamnagar supersite is 68.2 Million Tons Per Annum (MMTPA).
The Jamnagar refinery, started operations at 18 MMTPA, in 1999. The existing
refining capacity was enhanced to 33 MMTPA, via debottlenecking + value / product
maximization, plus a new 26.7 MMTPA refinery capacity added, subsequent to
obtaining the environmental clearance from the Ministry of Environment and Forest
(MoEF), for 59.7 MMTPA, in 2005. Further expansion to 68.2 MMTPA was
operationalized, in 2011, after obtaining Environmental Clearance from MoEF, in
2010.
The Jamnagar supersite is a global refinery icon, because:
• Largest refinery, at a single location
• Largest refinery off-gas cracker, for deep refinery-petrochemical integration
• Largest petcoke gasification, for a “bottom-less” refinery
• High complexity, for maximum crude-to-product flexibility
• High energy efficiency, for low ecological footprint
• Advanced automation, for effective monitoring, control and optimization
The Jamnagar supersite represents the pride of a resurgent India.
Aligned to the national “Make-in-India” objective, RIL plans to optimally leverage the
Jamnagar refinery + gasification assets, as a future growth platform, to maximize
petrochemicals, termed as “crude-to-chemicals”.

1.1. Need for the Proposed Projects.

The proposed Jamnagar growth projects shall boost India’s development and
prosperity objectives. Following strategies have been adopted for RIL’s future
projects in Jamnagar.
• Upgrade advantage Jamnagar feeds, via molecule management, to value-
added petrochemicals and thereby reduce India’s high chemical imports.
• Employ disruptive technology innovation to minimize the cost of chemicals to
ensure global competitiveness
• Supply competitive chemicals for labour-intensive secondary and tertiary
processing sectors to boost India’s employment potential
• Usher in future-forward digitalization technology for “Smart Manufacturing”
• Leverage existing assets to cost-efficiently transform Jamnagar for crude-to-
chemical
• Ensure responsible, circular use of chemicals to eliminate the scourge of plastic
waste
The proposed crude-to-chemical mission shall leverage following advantage feeds
for competitive chemicals:
• Reroute petcoke gasification derived syngas + CO from fuel to C1 chemicals
• Upgrade refinery streams, to olefins-based C2 + C3 chemicals.
• Value add C6 - C11 streams to aromatics-based chemicals
• Ultimate goal is to maximize value

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1.1.1. Multi-Feed Steam Cracker (MFSC)
Maximize chemical monomers, by upgrading refinery’s saturated light streams,
priced lower than crude, via stream cracking, in a MFSC.
1.1.2. Multi-zone catalytic cracking (MCC):
Further, maximize chemical monomers, by upgrading refinery unsaturated light
streams + heavy streams, via catalytic cracking. MCC represents the ultimate in
catalytic cracking conversion + severity, termed as an ultra-severity FCC.
The existing FCCs at Jamnagar shall be sequentially converted to high severity
FCC or Petro FCC. Petro FCC maximizes olefins + aromatics instead of gasoline.
The Jamnagar crude-to-chemical transformation is accomplished by an optimal
combination of MFSC + PetroFCC conversion + MCC
1.1.3. C1 complex
The petcoke gasification generates carbon-rich syngas, an excellent feedstock for
carbon-rich C1 chemicals. The Jamnagar growth projects propose to leverage this
CO-rich syngas, as a fountainhead for a world-scale + world-class C1 complex,
comprising of the following indispensable C1 chemicals:
• Acetic acid
• Acetic anhydride
• Acetic acid derivatives of ethyl acetate + VAM, or vinyl acetate monomer
• VAM derivative of VAE or vinyl acetate ethylene
• DME, or di-methyl ether

DME is especially versatile, as both fuel + petrochemical feedstock. The Jamnagar

DME shall be shipped to other RIL sites, to convert to olefins.
1.1.4. C2 complex
Ethylene shall be sourced primarily from the MFSC + MCC + ROG Cracker
debottlenecking.
Petro FCC conversion increases C2 content in the refinery off-gas, requiring a ROG
Cracker debottlenecking for additional ethane-to-ethylene.
This ethylene shall be the building block for the following C2 chemicals:
• Poly ethylene
• Ethylene oxide + MEG or mono ethylene glycol
• Ethylene oxide derivatives of DEG and TEG
• EDC + VCM + PVC for the vinyl chain

These C2 chemicals are vital because MEG a fibre intermediate, can clothe India
and PVC, used for pipes, can support India’s agriculture + housing sectors.
1.1.5. C3 complex
Propylene shall be sourced primarily from the MCC + MFSC.
This propylene shall be the building block for the following C3 chemicals:
• Poly propylene
• Acrylic acid
• Acrylic acid derivatives of acrylates + SAP
• Oxo alcohols
• Cumene + phenol/acetone
• Acetone derivative of iso-propyl alcohol
• Phenol derivative of polycarbonate, via non-phosgene, safe processing
• PO or propylene oxide
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• PO derivative of polyols
Acrylic chemicals support paints for housing and hygiene products. Phenolic
chemicals support engineering plastics to light-weight transport. Polyols
support polyurethanes a wonder plastic with diversified uses.
1.1.6. C4 complex
Butadiene shall be generated as a co-product from MFSC, supplemented by on-
purpose dehydrogenation of butenes.
The Jamnagar butadiene shall be shipped to other Reliance sites, to feed SBR or
styrene butadiene rubber + PBR or poly butadiene rubber.
1.1.7. Aromatics complex
Benzene, an exportable Jamnagar surplus, shall be supplemented by MFSC +
MCC, via BTX extraction.
This benzene, shall be the building block for following benzene based chemicals:
• Styrene
• Polystyrene

Refinery C7 shall be upgraded to maximum toluene, in a high-severity catalytic

reformer.
Toluene, sourced from BTX extraction + high-severity catalytic reformer, shall be
converted to additional xylenes via new toluene methylation + debottlenecking
alkylation.
Mixed xylenes, sourced from BTX extraction + toluene methylation + transalkylation
shall maximize PX, via PX recovery.
The Jamnagar PX shall be shipped to other RIL sites, to feed PTA + polyester for
labour - intensive textile sector.
1.2. Proposed Land Use
For setting up the crude-to-chemical growth projects in Jamnagar, RIL proposes to
develop a total area of 2000 acres adjacent to the existing Jamnagar supersite.
The plot plan indicating the location of the proposed projects are enclosed as
Figure 1.1.
1.3. Project Setting
Jamnagar district lies in the peninsular region of North West, India, in the state of
Gujarat, known as Saurashtra. The Jamnagar district boundary to the north is the
Gulf of Kutch, to the East by Rajkot district, to the South by Junagadh district and
to the West by Devbhoomi Dwarka District and the Arabian Sea.
The Jamnagar region falls in an arid zone. The area is covered by Deccan trap
basalt of cretaceous age. Existing land use is mainly scrub land (wasteland),
followed by fallow land. The site has been selected for the development of proposed
projects because it does not compete with agriculture or farming.
Recent, industrial development by public sector undertakings, private sector
organizations and port development has ushered in a recognizable economic boom,
leading to all-round prosperity + higher standard of living in Jamnagar + surrounding
areas.
The latitude and longitude of the center of the proposed complex is 22o20.115’N
and 69o53.247’ E.
Jamnagar is a recognized centre for the Brass industry + Bandhani fabrics (tie-&-
dye work on fabrics) + Zari sarees + Silk & Gold embroidery. Other major
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manufacturing sites in the adjoining area include Thermal Power Plant of the
Gujarat Electricity Board, Cement manufacturing unit of Digvijay Cements, Refinery
of Nayara, earlier Essar, and a Fertilizer unit of the Gujarat State Fertilizer
Corporation.
Other industries, including agro & food processing, biotechnology, chemicals &
allied industry, drugs & pharmaceuticals, gems & jewelry, engineering including
automotive, are also located in the Jamnagar district of Gujarat.
The existing industrial estates by GIDC around the Jamnagar site include:
• Shankar Tekri industrial estate, Jamnagar1
• Kamsudra industrial estate, Jamnagar 2
• Dared industrial estate, Jamnagar 3
• Jam Khambhaliya industrial estate
• Bhatia (RIDC)
The following siting criteria, delineated by MoEF&CC, New Delhi has been strictly
followed by RIL, for locating the proposed projects:
• The project will be located on barren land and the proposed expansion shall
be within the land belonging to RIL.
• The land proposed for expansion is a barren arid land and has sufficient space
to provide for a green belt.
• Layout and form of the project will conform to the landscape, without affecting
any geographical features.
• The scenic beauty of the area shall increase with the green belt around
proposed growth projects.
• Associated township for the proposed growth project can be developed taking
into account the predominant + prevailing wind direction.
• The proposed growth projects will not fall within the prohibited CRZ area or
the forest area.
In addition to the siting criteria listed above, the proposed project location has been
reviewed for the following salient features:
• Although the site is not prone to natural disasters, the proposed growth
projects shall be designed to the seismic codes specified by ISI and allied
agencies. It is pertinent to note that Gujarat Earthquake of 2002 with epicenter
near Bhuj, did not adversely impact the integrity of the Jamnagar Refinery.
• The process, for which environment clearance (EC) has been available since
2010.
• Water for operation will be made available from the proposed desalination
plant.
• Roads with adequate width and capacity are available to handle the increase
in traffic load.
• Construction materials will be principally sourced from local & neighboring
area to avoid long distance transportation. Stone chips and aggregates for
construction will be sourced from within the land acquired by RIL, to be mixed
in batching plants. Sand will be sourced from govt. approved vendors /
quarries.

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1.4. Locational Advantages
The principal drivers for the proposed growth projects in Jamnagar are:
• Maximize value addition of crude refined.
• Minimize the cost of production, with process integration + technology
innovation.
• Exploit economies of scale to ensure capex competitiveness.
• Ensure sustainability, with bespoke application + circularity adoption.
• Leverage world class infrastructure and logistics facilities at Jamnagar to
ensure global competitiveness.
Proposed growth projects in Jamnagar leverages the following strengths.
• RIL has a successful track record in executing mega + technically complex
projects, upholding the highest standards of health, safety and environmental
protection.
• An enviable project implementation record of high quality + low capex +
accelerated schedule
• The material supply, in the form of polymers + polyesters, shall spawn
ancillary and derivative industries, with high employment + import substitution
potentials.
• Jamnagar is ideally located in western India, having the highest chemical/
polymer consumption + established secondary processing platform for easy
product absorption.
• Access to the deep draft port facilities shall streamline machinery intake +
product offtake.
• The proposed project location meets the following siting criteria/guidelines of
the MoEF:
➢ Located away from the CRZ areas
➢ Barren land
• The proposed project location is well connected with the national and state
highways.
1.5. Proposed Projects
The details of the proposed projects are given in Table 1.1. In addition to the projects
listed in Table 1.1 the infrastructure for storage and dispatch of the products will also
be established. This will include facilities for road and rail transportation, modification
of the existing marine facilities for solid handling etc. The residential township will also
be expanded for accommodating additional personnel / employees required for
construction as well as O & M of the projects.
1.6. Need for Environmental Clearance: Categorization of the Project
The company needs to obtain the Environmental Clearance prior to construction of
the proposed expansion projects as per the EIA Notification of 14th September 2006
including its amendments. The proposed projects, as per the Schedule of the EIA
Notification 2006, may be categorised to be covered by 1 (d) Thermal Power Plant, 4
(a) Petroleum Refining, 5(a) Fertilizers, 5(c) Petrochemical Complexes, 5(f)
Petrochemicals with Synthetic Rubbers and 1(a) mining of minor minerals .
The water requirement for the projects will be met by desalination and the return sea
water discharge from the desalination plant will require CRZ clearance for discharge
as it will be in CRZ IV region.
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Mining of minor minerals to source stone for crushing to stone chips, within the site,
will also be required to be approved vide the same clearance.
1.7. Capital Cost of the Project
The overall capital cost of the proposed project will be Rs. 70,000 Crores.
Table 1.1 - Details of the proposed unit capacities at JMD
Growth
Projects
Sr. Projects Capacity Feedstock Remarks

(kTA) Feed stock

A Building blocks
Conversion of
1 High severity FCCs FCCs to Petro Existing Petro FCC conversion
FCC
Heavy
VGO/HCGO +
2 MCC / HSFCC complex 320 kbpd feed New
cracked
naphtha
Light ends from
2.1 C2= + C3= Recovery 8500 C2= + C3=
MCC
Aromatic
2.2 BTX+ Extraction 3500 feed naphtha from
MCC
Toluene /
2.3 Toluene Methylation 2600 From BTX+ extraction
Methanol
2.4 Trans Alkylation 1000 feed C9+ feed From BTX+ extraction

2.5 Paraxylene 4000 PX + OX Mix Xylenes

2.6 Benzene 1600 Crude Benzene From BTX+ extraction

Propane /
3 ROG Cracker 520 C2= Debottlenecking
Off Gases
Multi-Feed Steam
4 PCN / LPG New
Cracker (MFSC) complex
4.1 C2= + C3= Recovery 4100 C2= + C3= Offgases / C3s From MFSC
Butadiene (BD)
4.2 700 C4 mix From MFSC
Extraction
Naphtha /
5 Aromatic complex 1300 PX Expansion
Methanol
Naphtha /
5.1 High Severity Reformer 90 kbpd feed New
Imports
B C1 Chemicals

6.1 Acetic Acid (AA) 3000 CO / Methanol

6.2 Acetic Anhydride 750 AA AA derivative

6.3 Ethyl Acetate 1500 AA / Ethanol AA derivative

6.4 VAM 1050 AA / C2= AA derivative

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6.5 VAE + EVA 900 VAM / C2= VAM derivative

6.6 Poly Vinyl Acetate (PVAc) 300 VAM VAM derivative

6.7 Poly Vinyl Alcohol (PVAL) 150 PVAc PVAc derivative

B C1 Chemicals

6.8 Formic Acid 400 CO Syngas derivative

6.9 DME 2700 Syngas Methanol substitute

6.10 Polyketone 350 CO / C2= Syngas derivative

6.11 Iso-Nonyl Alcohol (INA) 300 CO / C4= Syngas derivative

6.12 MMA 700 CO / C2= / C4= Syngas derivative

6.13 PMMA 350 MMA MMA derivative

Air Separation
6.14 Rare Gases 50 Xe+Kr+Ne+Ar
Unit
6.15 Methanol 3600 Syngas Syngas derivative

6.16 Ethanol 500 Syngas Syngas derivative

Incl. waste water
6.17 NH3 1500 Syngas / N2
recovery
6.18 Urea 2600 NH3 / CO2 NH3 derivative

C C2 Chemicals

7.1 VCM+PVC 4500 C2= / Chlorine EDC imports

7.2 MEG / DEG 4500 C2= / Oxygen

7.3 PE 3000 C2= Multi-grade

7.4 EPDM 240 C2= + C3= Elastomer

D C3 Chemicals

8.1 Acrylic Acid 720 C3=

8.2 Glacial Acrylic Acid 150 Acrylic Acid Acrylic Acid derivative

8.3 Oxo-Alcohols 740 C3=

8.4 Acrylates 800 Acrylic Acid Acrylic Acid derivative

8.5 Cumene 1500 C3= / Benzene Phenol intermediate

8.6 Phenol 1000 Cumene

8.7 Acetone 620 Cumene Phenol by product

Phenol /
8.8 Bisphenol-A (BPA) 500 Phenol derivative
Acetone
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8.9 Polycarbonate 600 BPA / EO Phenol derivative

8.10 Iso-Propyl Alcohol 250 Acetone Acetone derivative

D C3 Chemicals

8.11 Propylene Oxide (PO) 1000 C3=

Polyols/Propylene Glycol
8.12 800 PO PO derivative
(PG)
8.13 Polypropylene 5200 C3=

E C4 Chemicals

9.1 PBR 280 BD BD derivative

9.2 S-SBR 6500 BD / styrene BD derivative

F C6 and heavies

10.1 Styrene, Polystyrene (PS) 1000 Benzene / C2=

10.2 Carbon Black (CB) 600 CSO

Polyphenylene sulphide
10.3 315 Benzene + S
(PPS)
11 PDH 1500 C3= C3 Propane dehydro
Coke/coal
12 Petcoke gasifier 8250 Refinery / Debottlenecking
Import
Battery Manufacture and
13 35 Petcoke cinder Gasification
Metals recovery
Gas / Liquid
14 Power (MW) 2000
(Refinery)
Mining of minor minerals Within RIL land
15 25 Ha
(Stone chips) area

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Chapter 2

Project Description
2. Introduction
The Jamnagar Refinery complex comprises of 2 existing side-by-side refineries –
Domestic Tariff Area (DTA) and Special Economic Zone (SEZ), at Jamnagar,
Gujarat.
The Jamnagar refinery complex has processed 150+ crude grades, which
represents almost half of crudes grades traded globally. The Jamnagar refinery
complex primarily produces transportation fuels and petrochemical products.
Approx. 60% of products from the Jamnagar refinery complex are exported. The
Jamnagar refinery complex is integrated with petrochemicals, utilities & power and
ports & terminal facilities. Self-sufficiency in utilities and power is achieved, by sea
water desalination, captive power plant and recycle & reuse of water. Technology
is licensed from global licensing leaders for the Jamnagar refinery complex.
2.1. PetroFCC
Existing FCCs in the Jamnagar refinery complex maximizes yields of gasoline
followed by propylene + ethylene. Increasing the operating severity, these FCCs
can be converted to PetroFCC, which maximizes yields of propylene + ethylene

13
followed by gasoline. PetroFCC enables the Jamnagar transformation for oil-to-
chemicals.
2.2. MCC / High Severity FCC
Multi-zone catalytic cracking (MCC) an ultra-severity FCC or high severity FCC
(HSFCC) with customized catalyst, beyond the high severity PetroFCC. MCC /
HSFCC employs a FCC type reactor – regenerator platform. The different zones of
the MCC are optimized for the feed cracking propensity, with different cracking
severity + residence time, to maximize ethylene + propylene yields from a range of
feeds. Unlike Petro-FCC, MCC produces no gasoline, DME from the C1 complex
can be a beneficial co-feed to the MCC. The reactor effluents are then sent to main
fractionator for separation. The gases from main fractionator are concentrated in a
typical FCC gas plant, to be sent to C2= + C3= recovery section. The bottoms from
the main fractionator are recycled to the MCC reactor, after aromatics or BTX +
recovery.
The spent catalyst from reactor flows to regenerator where the deported carbon is
burnt off to regenerate the catalyst.
2.3. ROG Cracker
ROG Cracker is operating above nameplate capacity. The additional Propane feed
available at Jamnagar, will help to debottleneck the ROG Cracker. With additional
Propane cracking and utilization of all Off Gas feed from refinery (including
additional gases from revamp of DTA coker), ROG Cracker can be debottlenecked
to sweat existing assets for additional olefins.
2.4. Multi feed steam cracker (MFSC)
As the name indicates, MFSC can crack naphtha minus light streams in to ethylene
+ propylene + butadiene + BTX or petrochemical building blocks. The hot section of
the cracker consists of pyrolysis furnaces that crack the feedstock into ethylene,
propylene and other light hydrocarbons. The hydrocarbon feedstock is preheated
and cracked in the presence of steam in tubular SRT (Short Residence Time)
pyrolysis furnaces. The cracked hydrocarbon products exit the furnace at >820°C
and are rapidly quenched in the transfer line exchangers (TLE) that generate high
pressure steam to boost energy efficiency. The pyrolysis/ quench systems are often
designed to handle the full range of gaseous and liquid feedstock from ethane to
naphtha. The number of cracking furnaces required is determined by ethylene
output.
The MFSC comprises of the following constituent sections.
• Contaminant removal
• Cracking furnaces
• Primary fractionation
• Cracked gas compression and drying
• Cold box / demethanizer
• Refrigeration section
• Deethanizer/ethylene recovery
• Depropanize/propylene recovery
2.5. C2= + C3= recovery
The cracked gases from MCC + pyrolysis section of MFSC are routed to the
common, integrated cold section. They are quenched first. The heavy hydrocarbons
are separated from the light hydrocarbons. The light hydrocarbons are compressed,
dried and sent to a series of fractionators termed as the cold section of the MFSC
for primilary ethylene + propylene recovery. First fractionator is demethanizer which
separates the lightest gases, such as hydrogen and methane, out through the

14
overhead and into the cold box unit for providing cryogenic cooling of the cold
section. The bottoms stream of the demethanizer flows to the deethanizer where in
ethane, ethylene, and acetylene are recovered. The mixture is hydrogenated in an
Acetylene Convertor Reactor to reduce the acetylene levels to meet the final
ethylene product specifications. The effluent from the reactor is fractionated in the
C2 Splitter. Ethane leaves the bottom of the ethylene fractionator and is recycled
back to feed the cracking furnaces of MFSC. The final ethylene product stream
leaves the overhead of the C2 Splitter. The deethanizer bottoms and the heavy
hydrocarbons from the compression system are routed to depropanizer. Polymer-
grade propylene is produced by further purification of the depropanizer overhead;
the MA/PD convertor removes the methylacetylene and propadiene from the C3’s.
The C3’s are then split into the propylene product and propane. The depropanizer
bottoms are separated into mixed C5+ and mixed olefins for sales or use in other
process plants.
2.6. BTX+ extraction
BTX+ recovery technology uses extractive distillation to remove benzene, toluene,
xylene and A9–A11 aromatics (BTX+) from refinery, aromatics streams.
The BTX+ extraction process consists of two columns: an extractive distillation
column and a solvent recovery column. Hydrocarbon feed is preheated with hot
circulating solvent and fed at a mid-point into the extractive distillation column. Lean
solvent is fed at an upper point and selectively extracts the aromatics into the tower
bottoms in a vapor/liquid distillation operation. The non-aromatics hydrocarbons exit
from the top of the column. A portion of the overhead stream is returned to the top
of the column as reflux, which washes back any entrained solvent.
Rich solvent from the bottom of the column is routed to the solvent recovery column
(SRC), where the aromatics are stripped overhead. The SRC is operated under a
vacuum to reduce the boiling point at the bottom of the column.
Lean solvent from the bottom of the SRC is passed through a heat exchanger before
returning to the extractive distillation column. A small portion of the lean circulating
solvent is processed in a solvent regeneration step to remove heavy decomposition
products. The SRC overhead mixed aromatics product is routed to the purification
section, where it is fractionated to produce chemical-grade benzene, toluene,
xylenes and A9-A11 aromatics for downstream processing.
2.7. Toluene methylation
Toluene methylation is an effective and economical solution to maximize the PX
yields by adding the methyl group from low-cost methanol or DME to the aromatic
ring. DME / methanol and toluene, are fed to a reactor where in the toluene is
alkylated into xylenes. The reactor effluent is processed in the fractionation section
to produce the mixed xylene product. Unconverted toluene is separated and
recycled back to the reactor. C9+ aromatics fraction is also produced and
separated, and is available as feedstock to the transalkylation unit, as the C9+ cut
is rich in tri-methyl benzene.
2.8. Trans-alkylation
Trans-alkylation process produces benzene and xylenes through transalkylation of
the methyl groups from toluene and/or heavy aromatics streams. The technology
features zeolite catalyst and can accommodate varying ratios of feedstock, while
maintaining high activity and selectivity. The manufacturing process comprises of
three main processing areas: splitter, reactor, and stabilizer sections. The heavy-
aromatics stream (C9+ feed) is fed to the splitter. The overhead A9-A11 product is
the feed to the transalkylation reactor section. The splitter bottoms are exchanged
with other streams for heat recovery before leaving the system. The aromatic
product is mixed with toluene and hydrogen, vaporized, and fed to the reactor. The

15
reactor gaseous product is primarily unreacted hydrogen, which is recycled to the
reactor. The liquid product stream is subsequently stabilized to remove light
components. The resulting aromatics are routed to product fractionation to produce
the final benzene and xylene products. The reactor is charged with zeolite catalyst,
which exhibits both long life and good flexibility to feed stream variations including
substantial A11 aromatics.
2.9. Paraxylene (PX)
The Aromatics Complex comprises of Xylene Fractionation, Crystallization or
Selective Adsorption and Isomers units. Xylene Fractionation column feeds mixed
xylenes to the PX recovery process. PX is recovered from mixed xylenes, because
of differences in either crystallization or adsorption, leading to PX, with a purity of
99.8 wt%, and recovery of 94-97 wt% of PX in a single pass.
In crystallization, successive crystallization is performed in 3 stages and the PX
crystals are separated from the melt by multiple centrifuges.
In selective adsorption, PX gets adsorbed on molecular sieves and subsequently
desorbed to get high purity PX.
2.10. Butadiene extraction
Butadiene extraction uses N-methylpyrrolidone (NMP) as a selective solvent to
recover 1,3-butadiene from a crude C4 mix.
Before entering the extractive distillation, light components are separated from the
crude C4 mix in a pre-distillation column. Then the feedstock enters the main
washer column representing the first stage of the extractive distillation process.
Butadiene and a part of the butenes are absorbed in the NMP solvent fed in from
the top. The C4 raffinate is drawn off as the overhead product of the main washer
column.
In the second extractive distillation stage after washer and part of the rectifier
column separate the C4 acetylenes. In the degassing column the hydrocarbons are
stripped from the solvent and recycled to the rectifier column using a compressor.
The diluted C4 acetylenes are withdrawn as a side stream and, after passing a
scrubber, are discharged to battery limits. The crude butadiene from the second
stage of the extractive distillation is sent to the butadiene column for final
purification. The butadiene product is withdrawn as a liquid side stream.
2.11. High Severity Reformer
High severity reformer is used to maximize the naphtha conversion to Aromatics-
rich reformate, a feed source for PX recovery. High severity reformer adds a
supplementary stand-alone reactor to the standard, moving bed, 3 reactor
configuration to maximize C7 conversion to toluene. The reactors are integrated
with fired heaters to support the endothermic reforming or crystallization process to
aromatics. The reactors are supported by continuous catalyst regeneration. The
catalyst contains Platinum, noble metal. The reforming reaction is driven by high
temperature and low pressure, just above atmospheric.
2.12. C1 based Units
2.12.1. Acetic Acid
Methanol and carbon monoxide are fed to the reactor, containing acetic acid, water,
hydrogen iodide, methyl iodide, and the rhodium catalyst complex. Methanol reacts
with hydrogen iodide to form methyl iodide, and in presence of rhodium catalyst
reacts with carbon monoxide to yield product acetic acid.
Unconverted carbon monoxide leaves the top of the reactor and is cooled before
flashing. The overhead stream from the reactor contains acetic acid, methyl iodide,
water, methyl acetate, and traces of carbon monoxide and hydrogen iodide. This
16
stream is fed to the product separation column wherein a concentrated acetic acid
stream is recovered as a side stream containing water, methyl iodide, methyl
acetate, and traces of hydrogen iodide.
The concentrated acetic acid side stream from the product separation column is
sent to the crude acetic acid column for further purification. The bottoms product
from the crude acetic acid column consists of acetic acid with traces of water and
hydrogen iodide. The acetic acid stream containing traces of water and iodine is fed
to the acetic acid finishing column. High purity acetic acid is removed as a liquid
side draw near the top of the column.
2.12.2. Acetic Anhydride
Acetic anhydride is manufactured by dehydration of acetic acid via ketene. Acetic
acid is first thermally dissociated into ketene and H2O, in the presence of tri-ethyl
phosphate, at 700 - 750 °C and reduced pressure. The higher boiling components
(acetic anhydride, acetic acid, and water) are separated from the gaseous ketene
in a system of graduated coolers. After removing the water, they are recycled to the
cracking stage. The ketene is fed directly into acetic acid, and converted at 45-55
°C and reduced pressures of 0.05-0.2 bar into acetic anhydride.
2.12.3. Ethyl Acetate
Ethyl acetate is synthesized via the Fischer esterification. Acetic acid and ethanol
are mixed in presence of acid catalyst at room temperature to yield ethyl acetate.
CH3CH2OH + CH3COOH → CH3COOCH2CH3 + H2O
Above reaction is an equilibrium reaction and yields 65% of ethyl acetate. To
enhance the conversion, the reaction is shifted by continuous removal of water.
2.12.4. Vinyl Acetate Monomer (VAM)
Gas, containing ethylene, oxygen and acetic acid, is passed through tubular
reactors containing supported palladium-gold and potassium acetate catalyst. At
high temperature and pressure, ethylene is converted to vinyl acetate. The reaction
product is cooled and the condensate is distilled to get vinyl acetate-water.
The distillate consisting of vinyl acetate and water is decanted with the organic layer
distilled to remove acetaldehyde. The crude vinyl acetate, free of light ends and
water is then further distilled and refined to pure vinyl acetate.
2.12.5. Vinyl Acetate Ethylene (VAE)
Vinyl acetate ethylene (VAE) emulsions are based on the copolymerization of vinyl
acetate and ethylene, in which the vinyl acetate content can range between 60 and
95 percent, and the ethylene content ranges between 5 and 40 percent of the total
formulation.
2.12.6. Ethylene Vinyl Acetate (EVA)
Ethylene Vinyl Acetate copolymer (EVA) is produced by the copolymerization
of Ethylene and Vinyl Acetate under pressure, using free-radical catalysts. Many
different grades are manufactured, with the Vinyl Acetate content varying from 5 to
60% by weight. High vinyl acetate content is termed as VAE. Low vinyl acetate is
termed as EVA
2.12.7. Polyvinyl Acetate
Polyvinyl acetate is produced through emulsion polymerization.
The process involves the reaction of monomer molecules of Vinyl Acetate by
submerging them into water resulting in the formation of a Polyvinyl
Acetate emulsion that is milky white in color.

17
2.12.8. Polyvinyl Alcohol
Polyvinyl alcohol is prepared by partial or complete hydrolysis of polyvinyl acetate
to remove acetate groups. The process of hydrolysis is based on the partial
replacement of ester group in vinyl acetate with the hydroxyl group, and is
completed in the presence of aqueous sodium hydroxide.
2.12.9. Formic acid
Methanol and carbon monoxide are combined in the presence of a strong base, to
form methyl formate. This reaction is performed in the liquid phase at elevated
pressure. Typical reaction conditions are 80 °C and 40 atm., with sodium methoxide
as base.
Hydrolysis of the methyl formate produces formic acid. Efficient hydrolysis of methyl
formate requires a large excess of water. For energy-efficient separation, the formic
acid is removed from excess water by liquid-liquid extraction, with an organic base.
2.12.10. Di Methyl Ether (DME)
The syngas, derived from petcoke gasification, is cooled, compressed and passed
to a tubular DME reactor. Reactor effluent is cooled, liquid separated and gas
recycled to synthesis loop. The crude DME is filtered and distilled in columns.
Syngas-to-DME shall be a 1-step process, employing novel, high stability catalyst.
2.12.11. Poly-ketones
Poly-ketones are semicrystalline thermoplastics formed by the copolymerization of
CO with ethylene.
A proprietary Palladium-based catalyst system is used for the liquid-phase
polymerization reaction of CO, ethylene, and propylene. Polymerization takes place
in a liquid reaction medium, of methanol, at 78-90°C and 45-50 bar. The reaction
products are cooled and depressurized to flash unconverted CO and olefins, which
are recycled to the process. The insoluble copolymer is concentrated and separated
from the mother liquor by a solid-liquid separation technique. The copolymer
product is then dried and bagged. Solvent is recovered through distillation or
evaporation and recycled to the process. Reaction by-products and spent catalyst
are discharged from the bottom of a distillation column/evaporator. These waste
streams are sent for recovery of associated palladium.
Polyketones are either copolymer of CO + C2= or terpolymer of CO + C2= and C3=
2.12.12. Isononyl Alcohol (INA)
Jamnagar is surplus in butenes. Dimarize butenes by liquid-phase oligomerization.
In the reaction section, dimerization takes place in multiple liquid-phase reactors
using homogeneous catalysis and an efficient recycle mixing system. The catalyst
is generated in situ by the reaction of components injected in the recycle loop.
The catalyst in the reactor effluent is deactivated in the neutralization section and
separated for safe disposal.
The stabilization section separates unreacted olefin monomer and saturates from
product dimers. The second column separates the octenes, and the third column
separates dodecenes. Nearly 80% conversion of butenes can be attained with 85%
selectivities toward octenes.
INA is obtained by hydroformylation of octene, to the corresponding C9 aldehydes
and the subsequent hydrogenation thereof.
2.12.13. Methyl Methacrylate (MMA)
This Isobutylene-based production of methyl methacrylate is a three-step process.
The process employs a Pd5Bi2Fe catalyst supported on finely divided SiO2-MgO.
18
In first step, isobutylene is sent through a vapour-phase fixed bed reactor with air or
oxygen. Methacrolein is produced at 96% conversion. About 4%, of methacrylic acid
is coproduced.
In the second step, the reactor effluents from first reactor are directly sent to a
second vapour phase reactor in which the methacrolein is converted to additional
methacrylic acid in about 76% yield.
Esterification of methacrolein takes place in a third slurry phase reactor with
methanol. In the final step of the process, methacrolein, methanol, and oxygen (air)
are reacted in the presence of a catalyst comprising transition metals such as nickel
or cobalt and gold nano-particles. The catalyst is supported on a silica-magnesia or
silica-alumina-magnesia carrier. The reaction takes place at 90–95°C and 85–110
psia. Methacrolein per-pass conversion is about 70%, and selectivity to MMA is 95–
97%.
2.12.14. Polymethyl Methacrylate (PMMA)
Polymethyl Methacrylate is the homopolymer of Methyl Methacrylate (MMA). PMMA
is produced through radical chain polymerization of MMA. Some product grades
require comonomers.
2.12.15. Rare gases
The six naturally occurring noble gases are helium, neon, argon, krypton and xenon
and the radioactive radon. Neon, argon, krypton, and xenon are obtained from air in
an air separation unit by liquefaction of gases and fractional distillation. Distillation
is a 2 step process for all rare gases except argon. First a concentrated solution is
made. Each rare gas, except argon, is separated by super fractionation.
2.12.16. Methanol
Methanol will be produced from Synthesis gas, a mixture of hydrogen, carbon
oxides, and methane under high pressure operations.
These gases react in the methanol converter in presence of Zinc-copper-aluminium
oxide catalyst to form methanol and water. Gases departing from the bottom of the
converter are cooled to condense crude methanol and water. This condensate flows
to a pressure blow-down drum and then to a crude methanol storage tank.
Uncondensed gases are recycled to the synthesis gas compressor.
The crude methanol is purified in fractional distillation column where low boiling
compounds, like dimethyl ether, are removed overhead.
2.12.17. Ethanol
Waste gases, from petcoke gasification, H2 recovery can synthesize ethanol via
bio-fermentation.
CO is the preferred feed for microbes. Pure CO2 can be added to saturate the
carbon requirements for the microbes.
The bio-process has multiple bio-reactors to which waste gas steam is fed for
fermentation which produces dilute ethanol mixture in water.
Fermentation media is fed to each bio-reactor to maintain optimal microbe
performance. The fermentation broth contains a gas-liquid mixture to provide
sufficient mass transfer between the phases.
Dilute ethanol is further concentrated and separated in vacuum column plus
rectification column followed by ethanol dehydration.

19
2.12.18. Ammonia (NH3)
Ammonia recovery from sour water
Sour water from refining + gasification process is passed through a de-gasser and
de-oiler, where light hydrocarbons and other dissolved gases are removed.
The degassed sour water is settled in tank, to remove entrained oil and solids, via
a solids filter and liquid-liquid coalescer. It is then fed to acid gas stripper, to remove
acid gases.
The acid gas stripper bottoms, is fed to the ammonia stripper. The overhead gas
contains raw ammonia. After purification, via water wash + caustic wash, the pure
ammonia is compressed with inter-stage cooling, and sent to storage.
Ammonia from syngas
Syngas is first shifted to produce H2. Hydrogen is then reacted with nitrogen to
produce Ammonia to supplement NH3 recovered from sour water.
2.12.19. Urea
Compressed CO2 and ammonia are mixed in the urea reactor to form urea. Weak
urea solution generated is concentrated in multiple stages. Final urea concentration
is done in evaporators.
2.13. C2 Based Units
2.13.1. Vinyl Chloride Monomer (VCM)
VCM is produced from ethylene-di-chloride and ethylene, over a mercuric chloride
catalyst to produce vinyl chloride. The reaction is exothermic and highly selective to
VCM, resulting in high yields + product purity.
2.13.2. Poly Vinyl Chloride(PVC)
PVC is produced by the suspension polymerization of VCM or vinyl chloride
monomer. VCM and water are introduced into the reactor along with a
polymerization initiator viz. dioctanoyl peroxide and/or dicetyl peroxydicarbonate.
The contents of the reaction vessel are continuously mixed to maintain the
suspension and ensure a uniform particle size of the PVC resin. The reaction is
exothermic and requires cooling. PVC is denser than VCM hence the volume is
reduced during the reaction, and hence water is continuously added to the mixture
to maintain the suspension. The average molecular weights range from 45,000 to
64,000. PVC slurry is degassed and stripped to remove excess VCM, which is
recycled. The polymer is then passed through a centrifuge to remove water. The
slurry is further dried in a hot air bed, and the resulting powder is sieved before
storage or pelletisation.
2.13.3. Ethylene Glycol (EG)
Principal EG products are mono ethylene glycol (MEG) and di ethylene glycol
(DEG). Ethylene glycol is produced from ethylene in a 2-step process via ethylene
oxide (EO) as an intermediate.
The MEG is produced by first converting ethylene-to-ethylene oxide (EO) through a
direct oxidation process and then hydrolyzing the same.
Ethylene, recycle gas and oxygen are thoroughly mixed, preheated and passed
through the EO reactor, where ethylene is converted into EO at elevated
temperature and pressure. The reaction product gas is scrubbed with neutralising
liquid to remove acidic compounds and further cooled in EO absorber by counter
contact with water, which absorbs EO and forms a dilute aqueous solution. The gas
after scrubbing and absorption of EO is recycled back to the reactor via a recycle
20
gas compressor. A small slip stream is taken to CO2 removal section for removal of
CO2 formed in the reactor, by absorption in hot potassium carbonate solution. Dilute
aqueous solution of EO in water is stripped off. EO from stripper are cooled,
condensed and purified by passing through light ends columns, which removes
lighter fractions. Purified EO mixture is heated, mixed with additional water and
passed through tubular glycol reactor. The reaction takes place in liquid phase
under elevated temperatures and pressure. The conversion is almost complete and
the glycol water mixture is sent for evaporation.
In evaporation section, water is separated from glycol mixture in a triple effect
evaporator with subsequent vacuum column.
Crude glycol mixture is separated into MEG, Diethylene Glycol (DEG) and Tri-
ethylene Glycol (TEG).
2.13.4. Poly Ethylene (PE)
Principal polymers of ethylene, or polyethylene, can be high density PE (HDPE),
low density PE (LDPE) and linear low density PE (LLDPE). The process involves
converting gaseous ethylene into solid phase PE by solution polymerization
process, using cyclo-hexanes as the solvent.
A purified solution of ethylene, solvent and co-monomer (octene or butene or both)
is fed to the reactor. Co-monomer is added for low-density PEs. Catalyst helps to
polymerise the ethylene and co-monomer. A chain terminator agent is used to
control molecular weight (polymer chain length).
About 95% of the ethylene is converted to PE on each pass. The molten polymer
solution flows to the extruder which feeds an underwater pelletizer. The pellets
formed are water conveyed to a continuous stripper to remove residual solvent,
which is condensed and recovered. The stripped PE pellets are dried and fed to
pneumatic blenders for blending into uniform lots.
2.13.5. Ethylene Propylene Diene Monomer (EPDM)
This process involves solution polymerization of monomers; ethylene, propylene
and diene in the presence of Ziegler Natta catalysts. The solution polymerization
process is the most widely used and is highly versatile for making a wide range of
EPDM Rubber grades. Ethylene, propylene and dienes are polymerized in the
presence of catalyst systems in an excess of hydrocarbon solvent. Stabilizers and
oils, if used, are added directly after polymerization. The polymer, which is in crumb
form, is dried with dewatering screens, mechanical presses and then by drying
ovens. The crumb is formed into wrapped bales or extruded into pellets. The high
viscosity crystalline polymers are sold in loosely compacted, friable bales or as
pellets. The amorphous polymer grades are typically packed in solid bales.
2.14. C3 Based Units
2.14.1. Acrylic acid
The propylene is oxidised with compressed air, and is converted into Acrolein and
further the Acrolein is oxidized to Acrylic Acid. The effluent gas containing Acrylic
Acid is quenched and absorbed with the descending water and the aqueous solution
of acrylic acid is obtained. Part of the off gas with non-condensables such as
acrolein, acetaldehyde, propane and unreacted propylene is recycled to the
oxidation reactor.
Water and acetic acid are eliminated by azeotropic distillation. Ester grade acrylic
acid is obtained from the top, while the bottom contains acrylic dimer and other
heavy ends. Aldehydes and ketones contained in the crude acrylic acid react with
the hydrazine hydrate forming hydrazone compounds. These are separated by
distillation in the High Purity Acrylic Acid (HPAA) distillation column.

21
2.14.2. Glacial acrylic acid
The acrylic acid monomer solution is purified to produce glacial acrylic acid which
can be polymerized to produce super absorbent polymer or SAP
2.14.3. Oxo-alcohols
2.14.3.1. n-Butanol
Syngas and propylene are fed to a primary hydroformylation reactor, over aqueous
catalyst solution of Rhodium complex. The effluent then passes to decanter to
separate the aqueous from the organic phase and to degas any entrained gases.
The product is then passed through a decanter to remove remaining aqueous
catalyst solution, prior to purification. The liquid effluent is distilled to separate the
aldehyde products from the catalyst and the high-boiling byproducts. The crude
butyraldehyde product from the secondary reactor system is combined with the
product from the primary reactor system for purification.
Butyraldehyde is fed to cross-countercurrent heat exchanger where it is mixed with
recycle H2 gas for hydrogenation to produce n-butanol.
2.14.3.2. 2-Ethyl Hexanol
2-Ethyl Hexanol is also produced by catalytic hydroformylation of propylene with
syngas, using rhodium catalysts. Since, the reactor effluent contains butanol and
water impurities, the crude 2-ethyl hexanol product is purified by fractionation.
2.14.4. Acrylates
n-Butylacrylate is produced by esterification of acrylic acid in presence of acid
catalyst. Acrylic acid and n-butanol in an equi-molar ratio are fed continuously to an
agitated reactor in presence of acid based catalyst and polymerizing agents. The
reactor is maintained at high temperature for faster reaction.
Ethyl acrylate is produced by substituting n-butanol with ethanol. Methyl acrylate is
produced by substituting alcohol with methanol. 2-ethyl hexyl acrylate is produced
by substituting alcohol with 2-ethyl hexanol.
2.14.4.1. Cumene
The Cumene process primarily consists of following sections:
• Alkylation: Alkylation of Benzene by propylene
• Benzene recovery: The benzene column recovers excess benzene from the
alkylation and transalkylation reactor effluents for recycle to the reactors,
removes the nonaromatic components which are contained in the benzene
feedstock, and dries the fresh benzene being fed to the unit.
• Cumene Column: The bottoms from the benzene column is fed to the cumene
column. This column separates the final cumene product from PIPB and
heavies. The column is reboiled by high pressure steam, and low pressure
steam is generated in the condenser. Cumene product is recovered as a
distillate and the bottoms are pumped to the PIPB column.
• PIPB Column: The PIPB column recovers DIPB and most of the TIPB from the
cumene column bottoms for recycle to the transalkylation reactor. PIPB is
recovered as a side stream from this column, and fed to the transalkylation
reactor for conversion to cumene.
• Transalkylation: The DIPB product from the PIPB column is mixed with
benzene, and fed to the transalkylation reactor. DIPB and TIPB are partially
converted to cumene with benzene. The effluent from the transalkylator flows to
the benzene column for removal of the excess benzene and the subsequent
recovery of cumene and PIPB.

22
2.14.4.2. Phenol and Acetone
Phenol and acetone are jointly produced from cumene by liquid phase oxidation of
cumene to cumenehydroperoxide (CHP) followed by catalytic de-composition of
CHP to phenol and acetone. Phenol, acetone, unconverted cumene, and by-
products are then distilled in a series of distillation towers to recover high purity
acetone and phenol, and recycle cumene.
Fresh and recycle cumene is fed to a series of oxidizers where cumene contacts air
and is converted to cumene hydroperoxide (CHP). Over-head vapors from the
oxidizers are cooled and condensed to recover cumene. Spent air is treated by
passing it through carbon beds to adsorb residual cumene.
2.14.4.3. Bis phenol A (BPA)
BPA is produced by the condensation of phenol and acetone in the presence of an
acid catalyst typically hydrochloric acid and methyl mercaptan as promoter. Acid
and phenol are recovered from the reactor effluents. The BPA is washed with water,
neutralised with calcium hydroxide and distilled under vacuum to purify the BPA.
2.14.4.4. Polycarbonate
Polycarbonate is produced by trans-esterification of di phenyl carbonate (DPC) with
BPA in two stages. The process is commonly known as melt process having
advantage of producing polycarbonate in undiluted form which can be directly
palletised.
DPC is produced by using an intermediate di-alkyl carbonate, usually dimethyl
carbonate (DMC), as the source of carbonate functionality. In first step phenol is
reacted with dimethyl carbonate to make phenyl methyl carbonate. In second step
phenyl methyl carbonate is reacted with phenol to convert to DPC.
BPA and DPC are reacted and phenol is removed to produce a pre-polymer of
Polycarbonate. Polymerisation to a higher molecular weight polycarbonate occurs
primarily through an ester disproportionation whereby DPC is formed and recycled.
2.14.5. Iso-propyl Alcohol (IPA)
IPA can be manufactured by indirect hydration of propylene, called the sulfuric-acid
process. In the indirect-hydration process, propylene is reacted with sulfuric acid to
produce mono- and di-isopropyl sulfates, which are then hydrolysed to isopropanol.
In the two-step strong-acid process, separate reactors are used for the propylene-
absorption phase and the hydrolysis of the sulfate esters. The reaction occurs at
high sulfuric acid concentration (> 80% wt) and low temperature (e.g. 20–30 °C).
2.14.6. Propylene Oxide (PO)
The unit consists of three process sections:
• Reduction and oxidation of a working solution
• Recovery and purification of hydrogen peroxide solution
• Working solution regeneration.
The working solution selected is a mixture of ethylanthraquinone (EAQ),
tetrahydroethylanthraquinone (THEAQ), its corresponding hydroquinone
(THEAHQ), and inert compounds in a mixed solvent of 21.4-wt% triethylhexyl
phosphate and 76.6-wt% aromatic solvent (mixed alkylbenzenes). The purified
product is a 37-wt% hydrogen peroxide solution. The propylene and hydrogen
peroxide solution flow counter-currently in the epoxidation reactors. The bottom
stream from reactor is fed into crude PO column. Crude PO stream is recovered as
overhead and is sent to the PO purification section for further purification to recover
PO with 99.98% purity. The TBA/water solvent is recycled after the removal of
methanol in column.
23
2.14.7. Polyols / Propylene Glycol (PG)
Catalytic polymerization of PO result in the production of polyols.
Propylene Glycol is produced by high pressure, high temperature, noncatalytic
hydrolysis of Propylene Oxide. A large excess of water is used in the conversion
of Propylene Oxide to a mixture of Mono-, Di-, and Tripropylene Glycols. This
increases the selectivity of desired Mono-product. Water is recycled. Typical
product distribution is 90% Propylene Glycol and 10% coproducts.
2.14.8. Polypropylene (PP)
PP can be in 3 product forms, termed as either homopolymer or random copolymer
or impact copolymer.
Propylene polymerisation to PP, in presence of hydrogen and catalyst, in a fluidized
bed reactor form homopolymer resin.
Polymerisation of ethylene and propylene to PP in presence of hydrogen and
catalyst in a fluidized bed reactor form random copolymer resin.
Homopolymer PP reacted further, with ethylene, propylene and hydrogen in a
second reactor form impact copolymer resin.
Only one type of resin can be produced per line in a batch mode. The resin is then
sent to resin degassing and unreacted monomers are sent to vent recovery and are
recycled back to reactors after separation.
Wet degassed resin is sent to finishing section, wherein additives are added to
stabilize the resin, and extrude it to pellets of uniform size.
2.15. C4 Based Units
2.15.1. PBR
First step is purification of solvent and monomers through distillation operations,
and catalyst preparation. It is fed to the first reactor of the polymerization train. The
dry mix feed (butadiene and hexane) coming from the purification systems is fed to
the reactor together with the catalyst solution. Butadiene polymerization takes
place in continuous stirred reactors operating in series.
The polymer solution leaving the reactors is mixed with the stopping agent to
destroy the catalyst and then is discharged into blend tanks in order to homogenize
the product. Vapor coming from blend tanks are condensed and sent to column to
separate and recycle the non-reacted monomer. The blended solution with the
antioxidant agents is fed to the stripping section where the solvent is removed by
steam distillation in the presence of a dispersing agent aimed to control the crumb
size in the slurry.
The crumb slurry is then pumped to the finishing unit, where the crumb is dewatered
on a shaker screen, being the water partly re-circulated to the strippers and partly
sent to waste water treatment. The vapors obtained from the stripping section are
otherwise condensed and the solvent, separated from water by a decanter, is sent
to the wet solvent tank. The dewatered crumbs are dried in two mechanical
extruders in series, cooled with air, weighed and baled.
2.15.2. S-SBR
Fresh butadiene and styrene are received, stored, and blended with recovered
butadiene and styrene. The two chemicals, along with a catalyst and soap solution,
are pumped to the reactors where polymerization takes place. After the short-stop
stage, in which an agent is added to the mixture in order to stop the reaction,
unreacted butadiene and styrene are recovered for recycling and pumped back to
the storage tanks. In the next stage, stripped latex is accumulated for blending, if
required. The latex is then coagulated and converted into crumb and screened,
24
washed, and filtered. Excess water is removed, and the crumb is dried in a hot-air
dryer. It is then weighed out in bales and wrapped in bags for shipment.
2.16. C6 + Units
2.16.1. Styrene / Polystyrene
The benzene and ethylene are fed to the zeolitic, liquid phase reactor. Ethylene
feed reacts completely, leaving only inert constituents. Poly ethyl benzene that are
produced by successive alkylalations are transalkylated with benzene to produce
additional EB.
The benzene column recovers and recycles benzene from the reactor effluent. Two
other columns recover EB which is sent to the dehydrogenation section, and PEBs
which are recycled to the reactor section. The EB is then catalytically
dehydrogenated to styrene in the presence of steam.
Polystyrene is formed from styrene through suspension polymerization, a process
by which tiny drops of the monomer (in this case, styrene) are completely
surrounded by water and a mucilaginous substance. Supporting and surrounding
the styrene globules, the suspension agent produces uniform droplets of
polystyrene.
Next, a polymerization initiator is added to the droplets, which are suspended by
heat radiation of about 100°C. This results in free radicals, a group of atoms
particularly likely to react with others because they contain unpaired electrons which
are available for molecular bonding. Free radicals then combine at randomly to form
chains of polystyrene.
Stopping the polymerization process is difficult. Terminators are introduced to the
process to end it at the appropriate time. Though variable, chain length must fall
within a certain range, because polystyrene with overly long chains won't melt
readily, and polystyrene with short chains will be brittle.
2.16.2. Carbon Black (CB)
Carbon Black is produced by partial oxidation of highly aromatic oils like CSO from
FCC. in a reactor. The reactor effluent is carbon laden flue gas along with some
combustible materials. Sensible heat from the flue gas is recovered in a waste heat
boiler to produce high pressure steam. Cooled flue gas containing carbon black
product is sent through bag filters to recover carbon black. Carbon black recovered
is sent to pelletizer and then to packing.
2.16.3. Poly-phenylene Sulfide (PPS)
Poly-phenylene sulphide (PPS), a form of engineering plastic is composed of
sulphur and benzene. Benzene reacted with sulphur to produce phenylene-
sulphide, which is then polymerized to PPS. Poly-phenylene sulphide can be
moulded, extruded, or machined to high tolerances.
The process is 2 step, a pre-polymerization, followed by polymerization.
This process replaces the conventional process which produces large quantity of
effluents, and also leads to presence of salts in the conventional PPS process.
Unlike conventional processes, it doesn't need solvent during polymerization of
PPS.
2.17. PDH
Propane, sourced from the refinery complex can be dehydrogenated to
propylene. Process is catalytic dehydrogenation of propane to propylene. The
unconverted propane is recycled back with the fresh propane.
There are 3 reactor options for the highly endothermic PDH reactions:
• Fixed bed, swing reactor, with heat generating matter
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• Moving bed reactor, with continuous catalyst regeneration
• Fluidized bed reactor- regenerator, similar to a FCC
The propylene-rich reactor effluent is compressed, dried and sent to a cryogenic
separator where hydrogen is recovered. The olefin product is then sent to a
selective hydrogenation process where dienes and acetylenes are saturated to
mono-olefins.
2.18. Petcoke Gasification:
The processing objectives for the expansion of Petcoke Gasification are:
• Support expanded crude oil refining and petrochemicals manufacturing, with
cost competitive, petcoke based energy supply
• Maximize reliability and availability of energy supply to the Jamnagar supersite
• Generate on-site syngas via petcoke gasification to minimize costly LNG
imports
• Reform CO2, a gasification waste, to manufacture additional syngas, as
petrochemicals feedstock
• Minimize carbon footprint + environmental impact with clean syngas instead of
dirty petcoke/coal via petcoke gasification
• Supply syngas as an advantage feed for the C1 chemical complex.
The gasification is partial oxidation of coke with O2. Coke gasification reaction
converts coke into syngas. The primary constituents of syngas are CO and H2.
Syngas can be a gas turbine fuel, which can produce power in a combined cycle.
Syngas can produce hydrogen, C1 chemicals and oxygenated chemicals.
The major elements or processing sections for the project are:
• Feed preparation to prepare petcoke/coal slurry to feed gasifier
• Gasification, partial oxidation at very high temperature to generate syngas
• Gas handling, to clean-up and cool raw syngas
• Sour block, to recover acid gases and generate sulphur
• Air Separation Unit (ASU) to supply O2
2.19. Battery Manufacture and Metals recovery
Batteries are basic components to ensure wide spread and efficient usage of
renewable energy. It is proposed to manufacture state of the art high capacity
batteries due to the resources available at Jamnagar. The high capacity batteries
will require raw materials like vanadium and Nickel.
Metals are natural ingredients of crude. In the refining and coking process these
metals are retained in the petcoke. In the process of Gasification of petcoke these
metals are retained in the petcoke cinder produced. The recovery of these metals
like Vanadium will provide valuable resources for the endeavor towards renewable
energy and India’s self sufficiency in valuable raw materials required for
manufacture of batteries using indigenously available materials.
Metals recovery is a combination of roasting + pyro-metallurgy + hydro-metallurgy.
Pyro-metallurgy can recover the metals as ferro-vanadium and Ni as ferro-nickel by
exploiting the eutectic temperature differences in a series of furnaces, to
progressively separate into metal phase. Further Hydro-metallurgy can recover V
as V2O5 from V rich intermediate sourced from the furnaces.
V2O5 is used as an electrolyte in large, stationery batteries to stabilize fluctuating,
renewable power grid. The metals so recovered are also important ingredients for
manufacture of stainless-steel.

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2.20. Captive Co-generation Gas/Liquid Based Power Plant
A Gas / liquid based power plant based on the cogeneration concept of GTs, STGs
& boilers will be installed for captive power and steam generation, to support the
Jamnagar Oil-to-Chemical project.

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Chapter 3

Environmental
Aspects
3.0 Environmental Aspects
Environmental aspects and impacts is a way of ‘mapping’ the environmental
consequences of the project. Every project has environmental aspects that can have
it’s impact on air, noise, water, land, biological and social impacts. One of the most
important considerations of the project should be identifying various environmental
aspects. Once the aspects are identified, several techniques and methodologies are
in vogue for predicting anticipated impacts due to projects on natural and social
aspects of the environment. These predictions are superimposed over the baseline
(pre-project) status of the environment to derive the ultimate scenario of
environmental conditions. These conditions are then subsequently evaluated for
acceptability by screening them against standards for ambient environmental
quality, against toxic effect, thresholds, etc. Based on results of prediction and
evaluation, pollution abatement and control measures in order to mitigate the
adverse impacts on the environment are delineated in an Environmental
Management Plan for further implementation during the construction and
commissioning of the proposed activities, as well as during the operational phase.
Impact predictions are made against a 'baseline' established by the existing
environment (or by its future state) known as baseline studies, the collection of data
on relevant biophysical, social and economic aspects provides a reference point
against which the characteristics and parameters of impact-related changes are
analysed and evaluated. In many cases, it is likely that the current baseline
conditions will still exist when a project is implemented.
The characteristics of environmental impacts to be taken into account in impact
prediction and decision-making include:
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i) Nature (positive, negative, direct, indirect, cumulative);
ii) Magnitude (severe, moderate, low);
iii) Extent/location (area/volume covered, distribution);
iv) Timing (during construction, operation, decommissioning, immediate,
delayed, rate of change);
v) Duration (short term, long term, intermittent, continuous);
vi) Reversibility/irreversibility;
vii) Likelihood (probability, uncertainty or confidence in the prediction); and
viii) Significance (local, regional, global)

3.1 Air Emissions

The impacts on air quality from any project depend on various factors like design
capacity, configuration, process technology, raw material/fuel used, envisaged
emission control measures, operational and maintenance practices. The emission
rates of air pollutants due to proposed operations will be considered for evaluating
their impact. The licensors will be required to meet the National standards
prescribed for every unit proposed to be set up. The stack details like stack height,
stack top internal diameter, stack gas velocity, stack gas temperature will also be
defined to facilitate the impact prediction. In the complex, stack emissions are the
major source of air pollution. Additionally, the logistics requirement will also be
established so that the transport requirements and its impact can also be
evaluated.

3.2 Water Requirement and Wastewater Generation

3.2.1 Water Requirement
Considering the water shortage in the region, seawater will be used for the proposed
projects after desalination to meet the water requirement, which will be used for
various purposes viz. service water, fire water, process water, boiler feed water,
cooling water etc. The water required will be supplied by the proposed desalination
plants. For this purpose, seawater will be supplied to the desalination units. The
desalination units proposed at Jamnagar will be combination of Thermal
Desalination Plant and Reverse Osmosis Plant, based on availability of steam.
The water requirement for the complex is currently being met by desalination of the
seawater. The Ministry has granted CRZ approval for intake of seawater and
desalination facilities in 2015.

3.2.2 Waste Water Generation

The wastewater generated from the proposed projects will be characterized and
quantified through the licensors so as to design the required treatment methodology
to meet the National standards. The wastewaters generated from the processes,
tank drainage from the proposed project area and sanitary sewage will be treated
at the Effluent Treatment Plant (ETP) to be set up for the projects.
In order to maximise the re-use of the wastewater within the J Complex, the
wastewaters will be segregated into low total dissolved solids (LTDS), oily water
sewer (OWS) and high total dissolved solids (HTDS) streams etc. Interconnectivity
through the plants will need to be provided, to enable maintenance to be selectively
carried out on the equipment within each treatment train. The refinery wastewater

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shall be collected via separate, dedicated effluent collection systems as required for
the optimum treatment and recycling.

The ETP will be designed to cope with the maximum oil & solids loading and the
sludge removal should be robust enough to operate given these peaks. A diversion
system will be used to store high volume flows (over the design flow) to the ETP in
a guard tank within the ETP prior to treatment. The ETP will be properly designed
considering the influent characteristics of the wastewater from different streams.
The treated effluent will be reused in the cooling towers to reduce the water
consumption within the complex.
The return seawater from the proposed desalination plant and the reject stream
from the tertiary treatment facility of the ETP will be discharged through the return
seawater pipeline and diffuser, the location of which will be identified by NIO.The
design of the discharge system will be at a point so located as to give the maximum
dispersion so as to minimize the foot print of the discharge and thus the impact.
3.3 Solid / Hazardous Waste Generation
The solid / hazardous waste expected to be generated from the proposed project
operations will be delineated by the licensors so as to design the storage facilities
for the type of wastes generated. The disposal of the generated waste will be
planned considering the hierarchy of the disposal methods with reuse and co-
processing given the topmost priority.
3.4 Biological Environment
No protected areas or eco-sensitive areas are located within the proposed project
area. Given that the potential impacts of operation and commissioning of the project
are likely to be localised, and good site management practices will be implemented,
no significant effects are anticipated. However, greenbelt in the Jamnagar complex
will be further strengthened, which will be a positive impact in the region.

3.5 Socio Economic Environment

Considering the size of the project, the direct and indirect employment will increase
tremendously. Approx. 50,000 construction workers and 1,000 operational workers
will benefit from the proposed projects. The proposed projects will also provide
indirect employment to the local inhabitants. The construction workers will be
housed in properly designed worker accommodation which will have proper
infrastructure provided so as to minimize the impacts on the surrounding population.

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