PETROLEUM

INDUSTRIAL

CHEMISTRY

PROJECT

Haldia Petrochemicals Ltd (HPL)

NAME – Kartikeya Tiwari

ROLL NO. - 08BT01209

GROUP - B3

INDEX

Sr. No. Topic Page no.

1. Abstract 3

2. Introduction 5

3. Products 9

4. Business Development 18

5 Figures (Illustrating Processes) 23

6 Conclusion, References 36-37and Acknowledgement

Abstract

Haldia Petrochemicals Limited | Email | Home

Haldia Petrochemicals Ltd (HPL)

Haldia Petrochemicals Ltd (HPL) is a competitive modern naphtha based Petrochemical Complex located 125 kms from Kolkata, at Haldia, West Bengal, India.

It is a prestigious Joint Venture project having the Government of West Bengal, The Chatterjee Group, the TATAs with the Indian Oil Corporation, etc. as major stakeholders with an investment of Rs 5864 crores.

The complex consists of a naphtha cracker unit and associated plants which manufacture:

Linear Low Density Polyethylene (LLDPE)

High Density Polyethylene (HDPE)

Polypropylene (PP)

Benzene

Butadiene

Cyclopentane

C4 Hydrogenated (LPG)

Pyrolysis Gasoline (Py Gas)

Carbon Black Feedstock (CBFS)

Motor-Spirit

HPL is the second largest petrochemical industry in India with a total capacity equivalent to 5, 20,000 TPA of ethylene. Process technologies for various manufacturing plants have been selected from internationally renowned vendors with an aim to produce world class products with excellent safety and environment considerations. Notable process technology suppliers and contractors for the project include -

Plant Technology ContractorNaphtha Cracker Unit Lummus, USA Toyo Engineering, Japan

Butadiene Extraction Unit BASF, Germany Lurgi, GermanyBenzene Extraction Unit Lurgi, Germany Lurgi, GermanyPyrolysis Gasoline Hydrogenation Unit

Axens, France Lurgi, Germany

C4 Hydrogenation Unit Axens, France SAIPEM, IndiaHigh Density Polyethylene Mitsui, Japan Daelim, South KoreaLinear Low Density Polyethylene Lyondell Basell, NetherlandsTechnimont, ItalyPolypropylene Lyondell Basell, NetherlandsDaelim, South Korea

In 2007 turnover exceeded 2 billion USD and PAT reached its maximum, Rs 581 cr. The financial indicators reflects sound health with expected Debt to Equity ratio at 1.10 at end of FY '08-'09 and Debt to Net Worth ratio expected to be strong at 0.75. Due to its strong financial performance and commitments, recently, ICRA has assigned highest credit rating of 'A1+' for the short term borrowing programs.HPL are a customer focused organization, recognized as a leading supplier of quality products and services.

A symbol of industrial resurgence in West Bengal, HPL has led the economic growth of the region by propelling significant investments in downstream processing industries, which generate huge employment opportunities for skilled and unskilled workers. Through strategic market focus, innovative product application development and excellent customer support services, HPL has played the role of a catalyst in emergence of more than 500 downstream processing industries in West Bengal with a capacity to process more than 3,50,000 TPA of polymers and generating more than 1,50,000 employment opportunities in the process. With dedicated efforts, HPL truly symbolizes its motto –

"Come Grow With Us".

Introduction

Board of Directors

Name

Mr Tarun DasChairman

Mr Pradip Roy

Dr Purnendu ChatterjeeDeputy Chairman

Mr Atul Kumar Rai

Mr Vijay K Chaudhry Dr Sabyasachi Sen, IAS Mr Subhasendu Chatterjee Mr R Vasudevan, IAS (Retd.) Mr Jamshyd N Godrej Mr Bhaskar Khulbe, IAS Mr Sushil Muhnot Dr Subrata Gupta, IAS Mr Sudesh Kumar Kapahi Mr Swapan Kumar Bhowmik

Managing DirectorMs Ramni Nirula

Major Milestones

Year Key Events

2007 Turnover exceeded 2 Billion USD. Reported maximum PAT since inception

2005 Capacity enhanced by 25%2004 Reported PAT for the first time. Turnover exceeded 1 Billion USD2003 Corporate Debt Restructuring (CDR) Approved

2001 Commercial production started.2000 Project Commissioned. Trial production started1997 Project construction started1996 Land Acquisition completed1994 MOU signed between WBIDC, Chatterjee Fund Management, Soros

Fund Management & Tata group of companies for implementation of HPL Complex through a joint venture co.

1992 Environmental Clearance of the project received1985 Incorporated as a public limited company

Financials

Performance of Haldia Petrochemicals Limited has been phenomenal since 2003-04. Overcoming the past setback and backed by significant turnaround, HPL had posted its maiden profit in 2003-04. During 2005-06, HPL wiped out all its accumulated losses and added Rs. 1,531.33 million to Reserves & Surplus and is standing at Rs. 7344.23 million as at March 31, 2007.

Backed by strong state-of-the-art technology, operating experience and committed efforts of highly skilled manpower, the Company consistently operated its plant at rates higher than the [declared] installed capacity. Naphtha Cracker capacity utilization during fiscal 2004-05, 2005-06 & 2006-07 were about 104%, 103% and 106%.

In fiscal 2004-05, 2005-06 and 2006-07, the net sales (net of excise duty) of the Company were Rs. 53,619.78 million, Rs.57518.70 million and Rs. 70873.70 million respectively, representing about 32% increase from fiscal 2004-05 to fiscal 2006-07.

The quality of HPL’s products remained World Standard and continued to be appreciated in domestic and international markets.

In 2006-07, polymers accounted for about 73% of the net sales as against 74% and 76% in 2005-06 and 2004-05 respectively. Chemicals accounted for about 27% of the turnover as against 26% and 24% in 2005-06 and 2004-05 respectively.

Sales in the domestic market accounted for about 77% of the net sales in 2006-07 as against 75% and 67% in 2005-06 and 2004-05 respectively while the export sales accounted for 23% as against 25% and 33% in 2005-06 and 2004-05 respectively.

Interest and financial charges reduced to Rs. 3,980.98 million in 2004-05 from Rs. 4,303.89 million in 2003-04 primarily due to implementation of CDR package. Interest expenditure further reduced from Rs. 3304.56 million in 2005-06 to Rs. 2820.09 million in fiscal 2006-07 due

to prepayment of debts, refinancing of External Commercial Borrowings and repayment of foreign currency debts.

During 2006-07, the Company recorded Profit Before Tax (PBT) of Rs. 8311.96 million, an increase of 70% over 2005-06 of Rs. 4879.73 million and increase of 16% over 2004-05 of Rs. 7153.95 million.

The performance of HPL during the year ended March 31, 2007 is as under:

Net Sales – Rs. 70873.70 million Operating Profit (EBITDA) – Rs. 14213.32 million Interest & Financial Charges – Rs. 2820.09 million Profit Before Taxation (PBT) - Rs. 8311.96 million

The Company is implementing expansion of capacity by about 30% which will take ethylene production capacity to 670 KTPA from the current level of 520 KTPA.

The Company is firmly moving ahead and aims at growing aggressively.

Vision

To be a profitable, efficient and customer focused organization, recognized as a leading supplier of quality products and services.

Delivering value to its shareholders.

Dedicated to achieve customer satisfaction.

Demanding, yet caring for its employees.

Demanding, yet fair and courteous to its vendors.

To be responsible as corporate citizen.

Corporate Social Responsibility

Being a responsible corporate citizen, HPL lays special emphasis on ensuring community welfare and protection of environment. Since inception, HPL management through several initiatives has ensured that harmonious relationship is maintained with the surrounding society and measures were taken to improve the conditions of the deprived people. HPL social initiatives are focused towards –

Improving quality of life of displaced people

Sustainable skill development

Health & Community Welfare

Educational & Social Causes

Environment Awareness & Protection.

Quality Policy

HPL is committed to total customer satisfaction; by delivering quality products and services through continuous improvement of knowledge, skills, processes and involvement of all employees and business associates. Quality Management System in HPL

HPL is committed to customer satisfaction by delivering world class quality products and services through customer focused product innovations, benchmarking and employing standardized proven work practices. The entire business operations are certified to international standard ISO 9001:2000 by DNV.

Energy Management System in HPL

HPL is committed to judicious use of energy for the production of quality goods & delivering world-class services to the customers. We strongly commit HPLselves to sustainable development by optimizing energy resources for efficient energy generation, energy conservation and application of renewable energy.

The salient features of HPL Energy Management System are as follows :

Dedicated Energy Management Group to steer energy conservation activities.

Regular internal & external audits to identify and implement energy conservation measures.

Well-established training, awareness recognition programmes to enhance employee involvement.

ProductsPolyethylene

Haldia Petrochemicals Limited is the second largest manufacturer of polyethylene in India with a total capacity of over 5, 00,000 tonnes per annum. It caters to more than 70% of the demand in eastern India and 30% on overall country basis. The product portfolio under polyethylene segment consists of various grades of High Density Polyethylene (HDPE) and Linear Low Density Polyethylene (LLDPE).

HPL manufactures a wide range of HDPE grades having narrow, medium & broad (bi-modal) molecular weight distribution using Mitsui Slurry CX Process to suit a wide range of end uses

HPL also manufacturers various grades of LLDPE in the swing LLDPE plant using Spherilene Gas Phase Swing Process from Basell, Netherlands. The LLDPE plant is the 3rd such plant worldwide using above technology and is used for manufacturing of various HDPE grades too.

These products from HPL are of benchmark quality, meeting the highest international standards and are used extensively by packaging, consumer durables, houseware, automobiles, furniture, container or luggage manufacturers in India and abroad. Due to superior quality, HPL products are in demand in various countries from EU, South East Asia, USA etc. HPL products are exported to more than 20 countries in the world.

Major Brands, Grades & End Uses

HDPE

Technology Partner – Mitsui, Japan

End Uses: Woven sacks; raschel bags for fruits & vegetables; containers for packaging edible oil, processed food, FMCG, lubricants, detergents, chemicals, pesticides; industrial crates &

containers; carrier bags; houseware; ropes & twines; pipes for water supply, irrigation; process industry & telecom.

Major grades under HDPE are –

HDPE

Technology Partner – Mitsui, Japan

End Uses: Woven sacks; raschel bags for fruits & vegetables; containers for packaging edible oil, processed food, FMCG, lubricants, detergents, chemicals, pesticides; industrial crates & containers; carrier bags; houseware; ropes & twines; pipes for water supply, irrigation; process industry & telecom.

Major grades under HDPE are –

A: Mitsui CX Process

Category Grade MFI Density Major Applications Datasheet MSDS

Film

F5400 0.09 0.954 General purpose film, Thin reinforced carry bags

F5400.pdf HD.pdf

HD T6 0.50 0.961 Lamination films, woven sacks and tarpaulin

HD T6.pdf

F5001 1.1 0.950 General purpuse Film and extrusion.

F5001.pdf

Raffia R5801 0.50 0.961 Stretched tape/raffia for woven sacks and tarpaulin

R5801.pdf

Blow Molding B5500 0.40 0.956 Medium to large bulk containers for chemicals, detergents or lube oil

B5500.pdf

B6401 0.40 0.964 Containers for lubricants and edible oil (up to 20 L)

B6401.pdf

E5201 0.35 0.952 High ESCR blow-molding, cable sheathing and jacketing, lamination and general purpose film,

E5201.pdf

extrusion applicationsE5201S 0.35 0.958 General purpose blow-

molding applicationsE5201S.pdf

Pipe P5300 0.25 0.948 PE 112 Pipe Applications P5300.pdf

Technology Partner – Basell

B: Spherilene Gas Phase Swing Process

Category Grade MFI Density Major Applications Datasheet MSDS

Mono-filament

HDT10 1.1 0.950 Monofilament for net, twines and ropes

HD T10.pdf

HD.pdf

HD T10S 1.1 0.950 Monofilament for net, twines and ropes

HD T10S.pdf

Raffia HD T9 1.1 0.950 Stretched tape/raffia for woven sacks and tarpaulin

HD T9.pdf

Injection Molding

M5018L 19.0 0.950 General purpose injection molded applications

M5018L.pdf

M6007L 7.5 0.950 Injection molding of heavy duty crates and industrial products

M6007L.pdf

M5025L 30.0 0.945 General purpose injection molded applications

M5025L.pdf

M6007LU7.5 0.950 Injection molding of heavy duty crates and industrial products with UV Stabilization

M6007LU.pdf

M5005L 4.5 0.950 Injection molding of heavy duty crates and industrial products

M5005L.pdf

M5002L 2.5 0.950 Injection molding of Caps and Closures

M5002L.pdf

Major grades under LLDPE are –

A: Spherilene Gas Phase Process

Category Grade MFI Density Major Applications Datasheet MSDS

Film

71601S 1.0 0.920 General purpose packaging film, drip laterals

71601S.pdf LLD.pdf

71601W 1.0 0.916 General purpose adhesive lamination film

71601W.pdf

71602S 2.0 0.920 General purpose packaging film

71602S.pdf

71602W 2.5 0.916 General purpose packaging film

71602W.pdf

71501S 1.0 0.920 General purpose packaging film

71501S.pdf

Drip Lateral 71601D 1.0 0.920 Drip laterals 71601D.pdf

Extrusion Coating

72307E 7.0 0.926 Extrusion coating of HDPE woven fabric, aluminum foil, jute, paper and allied substrates

72307E.pdf

Roto-molding 73005T 5.0 0.934 Tanks and container for domestic or industrial water storage, sanitation, agriculture

73005T.pdf

73005TU 5.0 0.934 UV stabilized tanks and container for domestic or industrial water storage, sanitation, agriculture

73005TU.pdf

73204T 5.0 0.932 Tanks and container for 73204T.pdf

LLDPE

Technology Partner – Spherilene , Basell

End Uses: General purpose packaging film, Rotomolded tanks, Drip lateral, Extrusion-coating of woven fabrics and low voltage power cables.

domestic or industrial water storage, sanitation, agriculture

XLPE Silane Grafting

LL T12 3.7 0.926 Low voltage power cable insulation

LL T12.pdf

Polypropylene

HPL manufactures more than 2, 75,000 tonnes polypropylene per annum using Spheripol-II technology supplied by Basell, Netherlands. Spheripol process is the most widely accepted technology for manufacturing Homopolymers and Copolymer grades. The unique process capabilities and high consistency in product morphology ensure excellent quality.

These products from HPL are of benchmark quality, meeting the highest international standards and are used extensively by packaging, consumer durables, houseware, furniture, container or luggage manufacturers in India and abroad. Due to superior quality, HPL products are in demand in various countries from EU, South East Asia, USA etc. HPL products are exported to several countries in the world.

Major Brands, Grades & End Uses

PP

Major grades under Polypropylene are –

A: Spheripol II Process

Category Grade MFI Density Major Applications Datasheet MSDS

Homopolymer - Extrusion

F103 3.0 0.90 BOPP Film Grade - General Purpose, Lamination & Metallizable films

F103.pdf PP.pdf

R103 3.0 0.90 Raffia Tapes ,Woven Sacks R103.pdf

Technology Partner – Basell, Netherlands

End Uses: Woven sacks for cement, foodgrains, sugar, fertilizers; leno bags for fruits & vegetables; TQ & BOPP films and containers for packaging textiles, processed food, FMCG; office stationary; components for automobile and consumer durables; molded furniture & luggage; houseware; geotextiles; fibers for socks, sports wear; soft luggage.

for Packaging Fertilizers, Cement, Polymers, Carpet Backing ,FIBC etc.

T103 3.0 0.90 Thermoformed Cups, Containers & Other disposable items

T103.pdf

F110 11.0 0.90 TQ and Cast Films for General Purpose Packaging etc.

F110.pdf

E116 16.0 0.90 General Purpose Extrusion Coating

E116.pdf

E125 25.0 0.90 Extrusion Coating of Woven Fabrics etc.

E125.pdf

Homopolymer – Injection Molding

M103 3.0 0.90 General Purpose Injection Molding

M103.pdf

M106 6.0 0.90 General Purpose Injection Molding

M106.pdf

M108 8.0 0.90 General Purpose Injection Molding

M108.pdf

M110 10.0 0.90 General Purpose Injection Molding, Furniture etc.

M110.pdf

Impact Copolymer – Injection Molding

M304 3.5 0.90 Automotive Components, Crates, Pails, Furniture etc.

M304.pdf

M310 10.0 0.90 Battery Boxes etc. M310.pdfM310S 10.0 0.90 Furniture, Pails,

Compounding, Automotive Components etc

M310S.pdf

M312 12.0 0.90 Compounding, Industrial Components, Automotive Components, Luggage, Pails, Houseware, Sanitary Wares etc.

M312.pdf

M311T 10.0 0.90 Compounding, Automotive Components, Luggage and Industrial Components

M311T.pdf

M325 25.0 0.90 Compounding, Automotive Components, Houseware, Appliances parts, Extrusion Coating

M325.pdf

M340 40.0 0.90 Appliance & White Goods, M340.pdf

Automotive component, Compounding,TWIM

Random Copolymer – Blow Molding

B200 1.9 0.90 General Purpose Blow Molded & Thermoformed Items, Sheets for Files & Folders.

B200.pdf

B202S 1.9 0.90 Bottle & Containers for Medical and Transparent Products (e.g. IV Fluid Bottles) etc

B202S.pdf

HPL can produce 170 KTPA Motor Spirit in both as per Euro II & Euro III Standard Specifications.HPL Motor Spirit Quality USP is :Motor Spirit is sold both in domestic markets mainly to Oil PSUs for and private retailers and is exported to South East Asia, Africa & Mediterrenean Europe. HPL is all geared up to produce the next grade of environment friendly low sulphur Motor Spirit as per Euro IV Standards.

Research Octane Number 92

High Purity, Low sulphur

Environment friendly as per Euro III Standards

Specifications MSDS

Gasoline or Motor Spirit is a petroleum-derived liquid mixture consisting mostly of aliphatic hydrocarbons and enhanced with aromatic hydrocarbons toluene, benzene or iso-octane to increase octane ratings, primarily used as fuel in internal combustion engines.

HPL makes Motor Spirit by adequate blending of Hydrogeneted Pyrolysis Gasoline with C5 and C6 raffinate.

Motor Spirit

C4 Hydrogenated (LPG)

Liquefied petroleum gas (also called LPG) is a mixture of hydrocarbon gases used as a fuel in heating appliances and vehicles.

HPL produces 110 KTPA LPG through hydrogenenation C4 Raffinate by IFP technology, licenced by IDEA, India. HPL LPG constitutes 100% Butane or Butane : Propane (90% : 10%) blend.

HPL LPG Quality USP :

Fully Saturated

Low Sulphur

High Octane

HPL sells LPG to both Oil PSUs and private retailers for sell in India. Major usage is in for household supply for domestic cooking & heating and some portion also go for industrial fuel usage. HPL is trying to make entry into HPL LPG usage in Auto-Fuel segment.

Specifications MSDS

Pyrolysis Gasoline

Raw Pyrolysis Gasoline (RPG) aromatics-rich naphtha-range stream produced in sizeable quantities by an ethylene plant when it cracks naphtha, butane or gasoil. Raw Pygas resembles reformate. It can serve as a high-octane blendstock for motor gasoline or as a feedstock for an aromatics extraction unit.

Hydrogeneted Pyrolysis Gasoline (HPG) obtained from RPG post Benzene extraction and is used as chemical feedstock for Aromatics – Toluene, mix-Xylene and low & heavy grade Fuel Oil. It is also used as gasoline blending component.

HPL has 170 KTPA capacity to produce HPG with IFP technology with licence from Lurgi, Grermany.

HPL HPG Quality USP is :

High Octane

Low Sulphur

Low Benzene

HPG is sold both in domestic markets mainly to Oil PSUs for gasoline blending and is exported to South East Asia, Africa & Mediterrenean Europe. HPL is also promoting use of HPG as chemical feedstock for value added extraction of chemicals - aromatics and fuel oil.

Specifications MSDS

Carbon Black Feedstock (CBFS)

Carbon black feed stock (CBFS) is the heavy hydrocarbon mix (above C9 to C15) bottom product of Naphtha cracker unit. CBFS is the key raw material used to manufacture carbon black. Roughly 2.2 tonnes of CBFS is required to produce one tonne of carbon black. Carbon black is basically used as a reinforcing agent in rubber products such as tyres, tubes, conveyer belts, cables and other mechanical rubber goods.

CBFS is also used as heating Fuel Oil in several industrial units.

HPL can produce 54 KTPA of CBFS which is sold to both Carbon Black manufacturing and for fuel oil usage.

HPL CBFS Quality USP :

Low heavy metals

Low sulphur

Awards & Achievements

HPL Achievements

Certification on ISO-14001 by M/s Det Norske Veritas, Netherlands.

Certification on OHSAS-18001 by M/s Det Norske Veritas, Netherlands.

British Safety Council's award of 5 STARS for Health & Safety Management Systems.

Ranked first for its Safety Management by Confederation of Indian Industry (CII), 2001-2002.

Ranked first for its excellent Environment & Safety Management by West Bengal Pollution Control Board and Indian Chamber of Commerce, 2002-2003.

ICMA (Indian Chemicals Manufacturers Association) Award 2002-03 for Excellence in Management of Health/Safety/Environment.

Marketing Set Up

Polymers are marketed through HPL 4 Regional offices and 6 area offices across the country. For details click on “Offices & Marketing Contacts”

Polymers

Linear Low Density Polyethylene (LLDPE)

High Density Polyethylene (HDPE)

Polypropylene (PP)

Chemicals

Benzene

Butadiene

Cyclopentane

C4 Hydrogenated (LPG)

Pyrolysis Gasoline (Py Gas)

Carbon Black Feedstock (CBFS)

Motor-Spirit

Business Development

Introduction

Business Development is of strategic importance to the growth of Haldia Petrochemicals Limited. A dedicated team of professionals act as a strong arm of the marketing team in developing plastic processing industry in West Bengal to promote HPL product consumption within the region and generate employment and economic prosperity in the region.

Objectives

Increase PO consumption in West Bengal & Eastern India

Creation of Plastics Processing Capacity

HPL’s Support for setting up of plastics downstream units

Development of Clusters – a cost effective manufacturing hub

Facilitating development of skilled manpower

Catalytic role in enhancing Export of Plastic Processed Products

Creation of Employment opportunities

Plastics & Environment

What we offer to encourage growth in plastic downstream industries?

1. Developing new applications – Geotextiles, Leno Bag, Food Packaging Containers, Tea Packaging, Rotomoulding and new market for the downstream industries

2. Support to the downstream processing industry by creating a wider market for their products.

3. HPL identifies buyers, develops product along with the vendors and facilitates smooth exports of plastics products.

4. Creating interest among investors about opportunities in plastics downstream industry

5. Direct Employment in the plastics processing industry

6. Significant indirect employment in transportation, casual work-force, infrastructure development and maintenance in industrial areas (food outlets, shops, public vehicle etc.).

Customer Services & Application Research

Customer Services (CS) group is dedicated to HPL’s polymer business activities. CS provides support and functions for continuous enhancement of customer satisfaction through polyolefin

product & application research. This is achieved by new product development and quality enhancement of existing products for changing customer needs.

Customer Focus

Customer Services plays catalytic roles in developing new customers & markets for HPL products. The activities of CS focus on:

Assisting customers for HPL grade selection

Extending technical support to customers

Providing processing guidelines and application related information

Providing testing and analytical support on raw materials and finished products

New product development and customization for specific market requirements

Conformance to statutory requirements for HPL products

Product positioning, trials and technical establishment

Monitoring customer feedback and optimization of product design

Customer Services functions as an interface between customers and the polyolefin manufacturing plants. The CS group works in tandem with the customers to understand their technical needs and help them achieve their business objectives with HPL’s products. CS interacts with customers to anticipate their emerging needs and future market requirements and initiates necessary measures for facing new challenges.Customer Services plays a key role in defining HPL’s product quality. This is augmented with periodic quality reviews and benchmarking.

Applied Research and Innovation

Since its inception CS has contributed to the growth of HPL by introducing, developing and retaining world-class quality products in a competitive market.

CS activities in the domain of Applied Research in polyolefins are tuned to serve HPL’s long term polymer business objectives. The research activities are guided by existing manufacturing capacities and challenges in times to come.

The polymer product basket of HPL is a manifestation of the innovative instincts augmented by rigorous evaluations and analytical initiatives of the CS team.

HPL polyolefin grades for the Indian and the Exports market:

Halene H (HDPE)Halene P (PP)Halene L (LLDPE)

The specialty products of HPL developed by CS group’s innovative ideas and efforts include

LLDPE grade for wire & cable applications , LLDPE drip lateral pipe grade , No break PP impact copolymer grade , High MFI HDPE for Injection Molding , Hi MFI PP Impact Copolymer for Compounding & Automotive applications, etc.

HPL enjoys major customer lock-in owing to the extensive support from CS. The sectors in which ‘Brand Halene’ enjoys customer preference in the Indian and overseas markets include HMHDPE film , HDPE Pipe , HDPE Blow Molding , PP Raffia , PP Thermoforming , PP Impact Copolymers for furniture , battery, automobile & luggage sectors, PP Random Copolymer for medical applications , HDPE Injection Molding, LLDPE Rotomolding,BOPP & TQPP films.

Performance Additives – Developments and Collaborations

CS team is responsible for performance additives as part of polyolefin product design. HPL polyolefin grades have been additivated to meet the processing as well as end use requirements of target sectors. These are reviewed and modified to meet the changing market needs of new processing machines and user preferences. CS ensures the additivation packages are designed to meet world class product performance.

New generation additives are evaluated to add value to HPL products and provide the same to the customers. CS collaborates with world leaders in additives to build a synergistic relationship that ensures that HPL products retain their edge over competitors. HPL has played key role in evaluating and launching new products from additive suppliers of international repute.

Plastic Machinery Tie-ups

CS interacts and works closely with plastics processing machinery & mold manufacturers. This exchange is focused towards the application areas and markets where HPL is currently present as well as for future expansion options. Leading Indian machinery manufacturers design and optimize their machine for throughput and end product quality based on HPL polyolefins. This provides particular advantage to customers adding new processing capacities and with plans to source raw materials from HPL

Knowledge Dissemination and Training Initiatives

Product Knowledge Programs are arranged by Customer Services to disseminate product related information. CS also organizes training programs for the benefit of plastic processing industries in bringing new concepts, exhibition of new products, sharing knowledge of latest technologies, development in plastics processing and applications.

Systems, Monitoring and Review

CS group has established quality management systems to measure, monitor and control quality and its improvements. The performance of CS is continually assessed through SQC tools,

external and internal customer surveys, auditing and self assessments.CS plans, performs and monitors its designated activities to conform to the organization’s Integrated Management Systems in line with ISO 9001 standards.

Facilities – Testing and Analysis

CS is equipped with a world class analytical laboratory for customer support to aid end-use development. The testing facilities include analysis of polyolefin properties covering areas like:

Polyolefin raw material:

Melt behavior and Flow

Density

Mechanical

SpectroscopyFinished Products:

Optical

Mechanical

Material identificationCS polyolefin processing facilities include:

Twin-screw compounding

Injection molding

Blow Molding

Blown film extrusion

Primary feedstock for HPL is Naphtha.

HPL consumes around 1.7 mmtpa of High Paraffinic Naphtha ( min 75% Paraffin and Max 6% Aromatics, Max 500 ppm Sulphur ) in its naphtha cracker unit at full throughput . In addition the complex also requires about 240,000 MT per annum of fuel grade Naphtha for use in their Captive power plant.

Post expansion HPL's requirement for feed would be enhanced to 2.2 mmtpa of Feed and 300,000 MT of Fuel Naphtha.

HPL's suppliers include International and Domestic Oil Majors like KPC- Kuwait, ADNOC- Abu Dhabi, BAPCO- Bahrain, Indian Oil Corporation, Bharat Petroleum etc as well as globally renowned traders like Glencore, Shell, BP, Vitol etc.

Naphtha is purchased both through Long Term Contracts via direct negotiation as well as through tender on Spot basis. Transportation of Feed Naphtha is through Clean Product Tankers in Parcel size of 25,000 MT or 50,000 MT (after Ship To Ship transfer at Vizag) with the cargos unloading at the adjacent Haldia Port.

Naphtha is stored at HPL’s plants in HPL storage tanks with a total capacity of around 120,000 MT which would go up to 150,000 MT post expansion. The tanks are connected to all the three Oil Jetties at Haldia Ports through dedicated Pipelines.

Figures (Illustrating the processes)

Petroleum Refining- The Mother Industry

Energy

Chemicals &

Fertilizers

Petrochemicals

Transport

Petroleum

Refining

95%

Polymer Processes (Used globally)

Ethylene to Polyethylene High pressure tubular process

(LDPE) LDPE, LLDPE, HDPE Chevron-Phillips slurry process

Basell Spherilene process ( LLDPE/HDPE)

NOVA- Sclairtech process ( LLDPE/HDPE)

Propylene to Polypropylene Basell Spheripol PP process

PP, PE Copolymers Dow UNIPOL PP process

Borstar PP process

CONCLUSION

The Indian Plastics Industry is well set on a high growth path and this can be achieved only by responsible participation of all the players in the Industry. HPL is a growth engine not only for West Bengal but for the whole of India.

PLANT CAPACITIESPlants Capacity Technology/Licensor

Nephtha Cracker (Ethylene) 420,000 TPA ABB Lummus, USA

PP 210,000 TPA Montell, Italy

LLDPE/HDPE (Swing) 225,000 TPA Montell, Italy

HDPE 200,000 TPA Mitsui, Japan

Butadiene 74,250 TPA BASF, Germany

Pyrolysis Gasoline Hydrogenation 117,400 TPA IFP, France

Benzene 77,050 TPA Lurgi, Germany

LSTK Constructors Units

Toyo Engineering Corporation, Japan

Naphtha Cracker

Daelim Engineering Company, Korea

PP

Daelim Engineering Company, Korea

HDPE

Tecnimont, Italy LLDPE

Lurgi, Germany Pyrolysis Gasoline Hydrogenation

Lurgi, Germany Benzene Extraction

Lurgi, Germany Butadiene Extraction

Its acceptance of environment friendly and convenient energy policy it is able to save lot of commercial savings.

ACKNOWLEDGEMENT

The given project report on Haldia Petrochemicals Limited was highly beneficial as it gave us an idea of the first step in the downstream petroleum industry. It is very important for us to know each of the process in details. I would like to thank Dr. Lalita Ladwani for giving us an opportunity in making this project successful.

Besides I would like to thank my friends Jinendra Chopra, Bhavik Shah and Harsh Jain who had helped me out in searching of various resources.

REFERENCES

Encyclopedia article

Wikipedia article

Pdfdatabase.com

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10 th Orientation Course in Catalysis for Research Scholars (28 th November to 16 th December,2009) Dr.K.R.Krishnamurthy, National Centre for Catalysis Research (NCCR-)Indian Institute of Technology

Chennai-600036-For the figures