AROMATICS&

DOWN STREAM PROCESS

T.K.BASAKGM(PC)

IOCL-RHQ

AROMATIC COMPLEX

• PX - ParaXylene

• PTA - Purified Terephthalic Acid( 1-4 Benzene Dicarboxylic Acid)

CH3

CH3

COOH

COOH

PX COMPLEX

NHTU

RAF. NAPHTHA

HYDROGEN

LPG

BENZENE

BENZENE & XYLENE

HY AROMATICS

O & M XYLENES

C9 AROM.

MIXEDXYLENES

C7- STREAMS

PX

CCRU

SULFOLANE BTF TATORAY

ISOMARPAREXXFUREFORMATE

HEART CUTNAPHTHA

TOLUENE

BZ & TOL.

MIXED XYLENES

PX Complex - Block Flow Diagram

Units in PXWhole complex divided into two blocks.PX-1

Naptha HydroTreater, Platformer/CCR UnitPSA, Recovery plus UnitBenzen Toluene Fractionation (BTF)Shell Sulfolane Unit (SSU),

PX-2Xylene Fractionation UnitParex UnitIsomar UnitTatoray Unit

PX-COMPLEXUNIT PURPOSE

NAPHTHA SPLITTER :- AT MATHURA

- AT PANIPATNAPHTHA HYDROTREATER/CCR PLATFORMER

XYLENE FRACTIONATION UNIT Splitting of the reformate i.e. separation of C6/C7 from C8+ streams to generate mixed xylenes

BENZENE/TOLUENE FRACTIONATION AND SULFOLANE EXTRACTION UNITS

Production of high purity benzene and toluene (to be used as secondary feedstock for increasing PX production)

PAREX For recovery of high purity Para-xylene from mixture of C8 aromatic isomers

ISOMER UNITFor re-establishing equilibrium mixture of isomers in the PAREX unit raffinate to improve the yield of Para-xylene

TATORAY UNITFor disproportionation and trans-alkylation of Toluene alongwith C9 aromatics for maximizing Para-xylene

Splitting of 110-165 Deg.C naphtha to arrive at the heart cut naphtha as feedstock for PX

Catalytic reforming of naphtha to enrich the aromatic precursors

PX BLOCK UNIT CAPACITYUNIT CAPACITY - KTA

NAPHTHA HYDROTREATING 500CCR 500

SHELL SULFOLANE EXTRACTION 152.2BTF 379.8

PAREX 2025.4XFU 481.7

TATORAY 360.2ISOMER 1656.5

Hydrotreated Naphthato CCR Platforming Unit

Light Endsto Fuel

StripperSeparator

SourWater

Make-upHydrogen

Water

NaphthaFeed

Feed Surge Drum

Heater

Reactor

NAPHTHA HYDROTREATING UNIT

FLOW DIAGRAM

NAPHTHA HYDROTREATING UNIT

FLOW DIAGRAM

CCR PLATFORMING UNIT FLOW DIAGRAM

CatalyseRegenerator

StackedReactor

Fresh Feed fromNaphtha Hydrotreater

Feed/ EffluentExchanger

Net Gas Recontacting Section

FreshCatalyst Fired Heaters

Reformate Productto Reformate Splitter

Debutanizer

Steam

Unstabilised LPG

Net HydrogenProduct

Note : Flue Gas from the convection sections of the fired heaters is typically used to generate high pressure steam. However, other heat integration options are available.

Recontacting Drum Chloride Treater

Benzene fromTatoray Unit

Reformate SplitterOverhead

Feed Surge Drum

Extractor

Raffinate Productto storage

AntiFoam

RaffinateWash Column

Steam

Stripper

MEA

Recovery Column

To Ejector

Extract to ClayTreaters in BT Frac. Unit

Steam

Steam

SolventRegenerator

Steam

Intermittent

WaterStripper

Make-upSolvent

SULPHOLANE UNIT FLOW DIAGRAM

SULPHOLANE UNIT FLOW DIAGRAM

Toluene ColumnBenzene Column

BenzeneProduct toStorageClay Treaters

Clay TreaterCharge Tank

RecoveryColumnOverheadsfrom Sulfolaneunit

HP Steam

Finishing ColumnOverheads fromParex unit

Stripper Bottoms from Tatoray Unit

16 ATA

Benzene Drag

C8+ aromatics toClay Treater Feed Heater at Xylene Fractionation Unit

Toluene to Feed SurgeDrum at Tatoray unit

BENZENE TOLUENE FRACTIONATION UNIT

PAREX UNIT FLOW DIAGRAMPAREX UNIT

FLOW DIAGRAM

Toluene to Tatoray Unit

Rotary Valve

Desorbent Surge Drum

Pump Out toTankage

DesorbentMake up

Heavies to Fuel Oil(Interm ittent)

S team

Raffinate to Isomar Unit

Raffinate Surge Drum

XyleneSplitterOverhead

Xy leneSplitterOverhead

Extract

Extrac t Column

FinishingColumn

p-XyleneProduct to S torage

Steam

24

131

12

Fixed fromXylene SplitterOverhead(via Isomar Unit)

W ater Injec tion

LineFlush

Seco

ndar

y Fl

ush

Des

orbe

nt

Parex Adsorbent Section

HeadFlush

Pusharound

FR

AR

FRC

D

EX

R

Hi

F

R

12

1 13

24PRC

HeadFlush

HeadFlush

HeadFlush

Ho

PRC

Pumparound

RV

Make-up Hydrogen fromTatoray or Platforming

Heater

ReactorSeparator

Parex Reffinate fromRaff. Surge Drum

Purge gas

Clay Treater

Dehepanizer Bottomsto Xylene Splitter

XyleneSplitterOverhead

DeheptanizerOvhd Liquid toPlatforming unitDebutanizer

Light Ends toFuel gas System

ISOMAR UNIT FLOW DIAGRAMISOMAR UNIT FLOW DIAGRAM

Toluene fromParex unit

C9 Aromaticsfrom A9 Column

Toluene fromToluene Column

Heater

ReactorSeparator

Feed Surge Drum

Recycle Gas

Purge Gas toIsomar Unit

Stripper

to Clay Treaters inBT Fractionation Unit Steam

Benzene to Sulfolane Unit

Ovhd Liquid to Platforming UnitDebutaniser

Liquid end tofuel gas system

BenzeneColumn

Make-up Hydrogenfrom Platforming unit

TATORAY UNIT FLOW DIAGRAMTATORAY UNIT FLOW DIAGRAM

PX Complex - Products(In Tons Per Annum)

CASE BOMBAY HIGH NAPHTHA

BONNY LIGHT NAPHTHA

FEED RATE 500,000 500,000 PRODUCTS

Paraxylene 361600 364200 Benzene 24100 32500 Raffinate Naphtha 26100 31000 Net H2 Rich gas 28000 35700 LPG 15000 12600 Light Ends 31000 14300 Heavies 14200 4700 Total 500,000 500,000

PTA

PTA PROCESS

1ST STAGE- OXIDATION PROCESSPARAXYLENE + OXYGEN = TA + H2O+HEAT

REACTION TAKES PLACE IN PRESENCE OF CATALYST & SOLVENT.

HEAT LIBERATION = 3000 KCALS/KG OF PX

P-XYLENE PARATOUALDEHYDE

PARATOLUIC ACID4-CARBOXY BENZALDEHYDE

TA

CH3

CH3

COOH

COOH

Com

pres

sed

Air

COOH

CHO

H2COOH

COOH

PARAXYLENE+ Acetic Acid

PA COMPRESSOR

CTA DRYER

PTA DRYER

CENTRIFUGES

OXIDATIONREACTORS

DISSOLVERREACTORCTA

CRYSTALLISERS PTA CRYSTALLISERS

ROTARY VACUUMFILTER

PRODUCT HOPPERS

ST C EM

Block Flow DiagramPTA Units

PURIFIED TEREPHTHALIC ACID - PROCESS

PTA CAPACITY IN INDIA

TMTPATMTPA

RIL Patalganga 1155 RIL Hazira 730 MCCPTA, Haldia 600+800 IOCL Panipat 553 Total 3838

PTA SUPPLY-DEMAND SCENARIO

YEAR 2009 2010 2015 2020DEMAND TMTPA 3162 3386 3973 4645

PTA DEMAND FORECAST BY NEXANTPTA DEMAND FORECAST BY NEXANT

••EXISTING INSTALLED CAPACITY : 3838 TMTPAEXISTING INSTALLED CAPACITY : 3838 TMTPA••TILL 2015, INSTALLED CAPCITY IS JUST SUFFICIENT TILL 2015, INSTALLED CAPCITY IS JUST SUFFICIENT

TO MEET MARKET DEMANDTO MEET MARKET DEMAND••IN FUTURE, GAP EXISTS & CALLS FOR ADDITIONAL IN FUTURE, GAP EXISTS & CALLS FOR ADDITIONAL

PTA CAPACITY.PTA CAPACITY.

POLYMERS

AROMATIC BASED POLYMERS - FEED STOCK

NAPHTAC5+AROMATICS

BENZENE O-XYLENE P-XYLENE

PS NYLONPETPSF/

PFY

Plasticizer,

Paint additive

PROPERTIES, QUALITY & APPLICATIONS OF CONDENSATION POLYMERS

POLYETHYLENE TEREPHTHALATE (PET)

PET STRUCTURE & SYNTHESIS

PET is a poly-condensation product of PTA and MEG

CH2 – CH2

- [O – (CH2)2 – O – C - C] -

OH OH O O

Manufacture Consists of two major steps:

1) Condensation Polymerization (CP)

2) Suspended Solid Polymerization (SSP) – to impart high molecular wt distribution and high intrinsic viscosity for bottle applications

COOH

COOH

Reactor-1Condensation

Polymerization

Reactor-2 suspended solidpolymerization*

ChippingSection

Final Crystallization

PET

* For improving intrinsic viscosity

PET PROCESS FLOW DIAGRAM

PET PROPERTIES

HardStiffStrongDimensionally stable material that absorbs very little waterGood gas barrier properties Good chemical resistance except to alkalis (which hydrolyze it)Crystallinity varies from amorphous to fairly high crystalline.Can be highly transparent and colorless but thicker sections are usually

opaque and off-white.Excellent electrical properties. High environmental stress crack resistanceVery good heat and heat ageing resistanceVery low creep, even at elevated temperatures

Grade Process/Technology

Intrinsic Viscosity

(dL/g)

Applications

Bottle Polycondensation/SSP

0.76-0.84 Bottled water, Carbonated soft drinks, Edible oil, Country Liquor, Pharmaceuticals

Cosmetics, Household jarsFilm Polycondensatio

n/Extrusion0.64-0.66 Packaging, Metallic yarn, Audio

video tapes, Power cables

Fibre Polycondensation/Extrusion/

Drawing Fibre

0.6-0.63 Fibres for a very wide range of textile & industrial uses

(Dacron®,Trevira®,Terylene®)

PET GRADES & APPLICATION

PET TECHNOLOGY OVERVIEW

Major Licensors:Zimmer AG, Germany

Invista (erstwhile Dupont), USA

Noyvalesina, Italy

Buehler, Switzerland

Polyester Staple Fibre (PSF)

PSF STRUCTURE & SYNTHESIS

PSF is also a poly-condensation product of PTA/DMT and MEG

CH2 – CH2

- [O – (CH2)2 – O – C - C] -

OH OH O O

Manufacture of PSF consists of 4 steps:

1) Polymerization: Using PTA/DMT and MEG on either batch orcontinuous polymerization forming final polymer

2) Melt spinning :Here molten polymer is forced through spinneret holes to form undrawn filaments, to which spin finish is appliedand coiled in can

COOH

COOH

3) Drawing: in which several million undrawn filaments are drawn or pulled approximately 4 times in 2 steps, annealed, quenched, crimped and crimp set and final textile spin finish applied

and

4) Cutting: in which the drawn crimped tow is cut to a desired 32/38/44/51 mm length and then baled to be transported to a blend spinning mill.

PSF STRUCTURE & SYNTHESIS (contd)

BalingSection

ReactorCondensation

PolymerizationSpinningSection

Draw Section

Cutting Section

PSF Bales

PSF PROCESS FLOW DIAGRAM

PSF PROPERTIESQuality is superior to cotton, viscose, wool etc. in terms of strength, evenness

values and imperfections.High resistance to extension deformation during mechanical processing. Tough, high flex life, abrasion resistance and shock absorbency.Good abrasion resistance gives fabrics better wear performance.Exhibit negligible creep.Poor electrical conductivity due to low moisture regain.Flammability is low. Not affected by dilute acids, chemical solvents and detergents used in cleaning.

Also shows high resistance to oxidizing and reducing agents. Recovers well from stretch, compression, bending and shear.Thereby causing lesser wrinkles and creases.Thermoplasticity of fibre ensures that fabrics do not shrink during usage.

Permanent pleats & embossed effects can be done on fabrics at high temperature & pressure.

PSF GRADES & APPLICATION

PSF fibres are available in 4 tenacity levels:

GRADE TENACITY(in grams

per denier)

Application

LOW PILL 3.0 – 3.5 Generally used for knitting

MEDIUM 4.8 – 5.0

HIGH 6.0 – 6.4

Apparel end use. High tenacity preferred since their use enables ring frames to run at high speeds, but their dyeablity is 20 to 25% poorer, have lower yield on wet processing, have tendency to form pills and generally

give harsher feel.

SUPER HIGH

7.0 plus used for spinning 100% polyester sewing threads & other industrial yarns

PSF TECHNOLOGY OVERVIEW

Major Licensors:Invista (erstwhile Dupont), USA

EMS- INVENTA

Zimmer AG, Germany

Noyvalesina, Italy

VALUE ADDITION FROM PTABY PRODUCTION OF

PBT

Poly butylene Terephthalate Production(PBT)

••Present demand in IndiaPresent demand in India--11 MMTPA11 MMTPA••Forecasted demand in India by 2025 Forecasted demand in India by 2025 -- 46 MMTPA46 MMTPA••Export potential existsExport potential exists••PBT resin price is more than double of PTAPBT resin price is more than double of PTA••PBT emerged on the market as a raw material for PBT emerged on the market as a raw material for synthetic fibers & engineering plastics used mostly in synthetic fibers & engineering plastics used mostly in Automotive sector, Electronic & Electrical sector and Automotive sector, Electronic & Electrical sector and appliance sector.appliance sector.

Thank You