by p.shyam kumar padc, panipat ministry of textile-ficci conference,ficci,new delhi 19 th nov 2010...
TRANSCRIPT
By
P.SHYAM KUMAR
PADC, Panipat
Ministry of Textile-FICCI Conference,FICCI ,New Delhi
19th Nov 2010
Content
Company Profile
IOCL in Petrochemicals
Polymer Plants & Technology
Geosynthetics & Applications
Raw Materials
Technical Support
Customer’s benefits & Opportunities
Company Profile
Diversified, Transnational, Integrated energy company
Fortune 500 Global company, ranked at 105th position in 2009
18th largest petroleum company in the World
Sales turnover in 2008 – 09 : 2,85,337 Cr (US $ 63 bn)
Indian Oil - An Overview
Indian Oil An Overview
Refinery
Marketing
Pipelines
R & D
Business Development
Owns 10 out of 19 Refineries in India
Refining Capacity – 60.20 MMTPA
Country’s largest network of
nearly 10,000 KM.
17,600 RO’s, 5000 LPG Distributors, 101 AFSs,
90 Bottling Plants, 200 Bulk storage terminals & depotsBio-fuels & Gas Marketing
Prod & Marketing : LAB, PTA & Polymers
3 overseas subsidiaries in
SL, Mauritius & Dubai
2100 Lube formulations
140 Patents
Indian Oil inPETROCHEMICALS
Indian Oil in Petrochemicals
Linear Alkyl Benzene at Gujarat Refinery Capacity – 120 TMT LAB, UOP Detal Process
Project Cost - Rs 1200 crore
Commissioned August 2004
Successfully operating at over 100% capacity
PX/PTA at Panipat Capacity 553 TMT PTA (Invista T 10 Technology)/ 370 TMT
PX, UOP Technology
Project Cost – Rs. 5000 crore
Commissioned June 2006
Successfully Operating at 100% capacity
Naptha Cracker & Downstream Polymer at Panipat Product : LLDPE, HDPE, PP,MEG, Benzene
Capex : Rs. 14000 Cr.
Commissioned April 2010
Polymer Plants & Technology
IOCL Polymer Plants & Technology
Sr. No Plant No. of Lines Capacity per Line (KTA) Technology/ Licensor
1 Polypropylene 2 300 Spheripol – Basell
2 Dedicated HDPE 1 300 Hostalen – Basell
3 HDPE / LLDPE Swing 1 350 Sclairtech - Nova
Polypropylene PlantPolypropylene Plant Dedicated HDPE PlantDedicated HDPE Plant Swing PlantSwing Plant
Spheripol Hostalen Sclairtech
“With 1.25 Million MT capacity, IOCL will be the second largest Polyolefin producer in India”
Spheripol Technology : Process Capability
• MFR: 0.3 - > 1600 g/10min
• Xylene Insoluble: 90 – 99 (wt)%
• Flexural Modulus 500 – 2200 MPa
• Izod Impact Strength up to 750 J/m
• SIT in RACO as low as 115°C
• MP 130 - 165 ° C
Polypropylene
Spheripol Technology Share : 45% (100 lines)
Global PP Capacity – 48 MMTA
Global PP Consumption – 46.5 MMTA
Site Photo : Spheripol Line of IOCL, Panipat
Hostalen Technology : Process capability
Dedicated HDPE
• Product Density - 0.94 – 0.965 gm/cc
• MFR - 2.2 (I21) to 60.0 (I5) dg/min
• Conversion rate up to 99.5 % for Ethylene.
• Excellent Quality & Product consistency.
• Bimodal grades.
Global HDPE Capacity – 33 MMTA
Global Consumption – 30.3 MMTA
7 MMTA of HDPE Produced by Hostalen Technology (36 lines)
Site Photo : Hostalen Line of IOCL, Panipat
Sclairtech Technology : Process Capability
Swing Unit (HD/LLDPE)
• Density – 0.905-0.965gm/cc
• MFI – 0.3 – 150 gm/10min
• High ethylene conversion > 98%
• Short residence time in the reactor
• Low gel level, lot-to-lot consistency
• Capability to produce C4, C8 & terpolymers
Sclairtech Capacity : 3.5 MMTA (11 lines)
Global PE Capacity – 77 MMTA
Global PE Consumption – 73.1 MMTA
Site Photo : Sclairtech Line of IOCL, Panipat
IOCL Polymer Grade Portfolio
Polyethylene
• LLDPE – 11 Grades – 0.9 MFI to 50 MFI (Butene & Octene)
• HDPE - 22 Grades – 0.1 MFI to 18 MFI (Unimodal & Bimodal)
All PE Grades will meet the requirements of IS : 10146-1982 for food contact applications, IS:10141-1982 positive list of constituents & US FDA: CFR Title 21,177.1520
Polypropylene
• Homo Polymer – 14 Grades – 2 MFI to 35 MFI
• Random Copolymers – 5 Grades - 1.8 MFI to 45 MFI (Clarified & GP)
• Impact Copolymers – 8 Grades – 3 MFI to 50 MFI (Medium to Super high
Impact)
All PP Grades will meet the requirements of IS : 10910 for food contact applications, IS:10909 positive list of constituents & US FDA: CFR Title 21,177.1520
Geosynthetics & Applications
Geosynthetics Family
Geosynthetics
Geotextiles
Woven
Slit Tape Multi Filament
Non-Woven
Needle Punched
Spun Bond
Geogrids (Woven) , Georopes, Geonets, Geocomposites, Geocells,
PVDs(PP) etc
Indian Scenario
Potential - 25KTA Imports - 53% Suppliers - 12
51
14
5
19
10
Global Trend in Geosynthetics
USA
EU
AUS
China
India
Other Asians
~250KTA
Applications & Functions
Application Areas
Roads (NHAI & NRRDA)
Railways
Ports & Airports
Coastal Protection
Ground Improvement
Functions
Separation
Reinforcement
Filtration & Drainage
Containment (barrier)
Protection
Raw Materials for Geosynthetics
Raw Materials for Geosynthetics
Polymers Used
PP ≈ 85 %
PET ≈ 12 %
PE ≈ 2 %
Nylon ≈ 1 % Polymer yarn used
PP Advantages
Lower density and MP
Low Cost
Availability
Good balance of properties
IOCL PP -Woven Grades for Geotech
Grade and Performance Attributes
Good processability
Good balance of tenacity & elongation.
Consistency in MFI gives excellent thickness control
Tailored additive package for lower water carryover
Grades are designed to give tenacity > 5gpd and elongation ~20%
Isotactic Index > 95%,with FM >1450MPa
PROPEL 1030RG
MFI- 3 (g/10min)
IOCL PP – F &F Grades for Geotech
Grades and Performance Attributes
Consistent medium to high melt flow
Narrow to medium molecular weight distribution
Tailored additive package
High purity
Low oligomer content
Tenacity of 2.5 - 4 g/den
% Elongation at break of 70 - 100
Exhibits higher tenacity on industrial scale
PROPEL 1120YG
MFI- 12 (g/10min)
PROPEL 1250YG
MFI- 25 (g/10min)
PROPEL 1350YG
MFI- 35 (g/10min)
Technical Support
PADC is being set up at Panipat (Haryana) near
Panipat Naphtha cracker Project (PNCP).
PADCPADC
PLANTPLANT
MarketingMarketing
CustomersCustomers
New Grade
development
Knowledge
Management
Customer
Relation
Management
Technical
Support to
Customers
New Application
development
PADCPADC
PADC is an interface between Plant,
Marketing & Customers
State of Art Technology Centre with sophisticated Plastic
Processing & Characterisation equipments
Product Application & Development Centre - PADC
Customer Benefits with IOCL Entry
• Ample raw material availability with IOCL entry
• Wider PP product portfolio due to 2 Spheripol lines.
• Plants incorporating latest developments & most sophisticated control systems for superior lot to lot consistency.
• Sizable plant capacities will help in stream-lining supply & pricing fluctuations which are frequently experienced in Indian market.
• IT Enablement – E Commerce module – Transparency and ease of transaction
• 1st PP plant in Northern region, which is 2nd largest consumption region in India – Northern Region has potential to be largest region
• Business opportunity with company trusted by Indians for over 50 years.
Thank youThank you
“Let’s work together for nurturing a long term business relation”
Back - Up
Panipat Naphtha Cracker Complex (PNCC)
• Ethylene- 857 KTA
• Propylene – 650 KTA
• Butadiene – 130 KTA
• Benzene – 130 KTA
• MEG 325 KTA
• 650 KTA PE and 600 KTA PP
Technology : ABB Lummus
Feedstock 2.3 MMTPA Naphtha
Naphtha Cracker Unit
IOCL PP : Product Attributes
High Yield High Yield High High
Selectivity Selectivity CatalystCatalyst
High Clarity of PPRCP GradesLow Seal Temp. Grades
High Ethylene Content ICPs
Low Ash ContentLow Odour
Compliance to FDAExcellent Organoleptic Properties
High Isotactic Index in PPHP
Bimodal GradesLot-to-lot
consistencyProduct
benchmarked in over 100 countries
Reactor Grades up to 100 MIReactor Grades up to 100 MIBroad MFR RangeBroad MFR Range
Excellent Extrusion Coating grades
Excellent Processability &Excellent Processability & High TenacityHigh Tenacity
27
IOCL PP : Product Envelope
Technology :Spheripol
Licensor : Basell
Plant capacity : 2 lines of 300 KTA each
Product : Polypropylene (Homo/RCP/ICP)
IOCL Homo Polymer
IOCL RCP
IOCL ICP
HO
MO
PO
LY
ME
RC
O P
OL
YM
ER
1 10 100
MFI (g/10min)
BOPP
RAFFIA
EBM
GP IM
TQPPCPP
F&F
TWIM
NON WOVEN
RCP EBM
RCP
GP EX
RCP
TWIM
RCP GP IM
RCP ISBM
ICP EC
ICP TWIM
ICP IM (GP/FURNITURE/BATTERY/AUTO)
IOCL HDPE (Hostalen Plant) : Product Attributes
29
Bimodal Pipe grades complying
PE63, PE80 & PE100
Requirements
Bimodal Pipe grades complying
PE63, PE80 & PE100
Requirements
0.940 – 0.965 g/ccup to 60 (I 5) dg/min0.940 – 0.965 g/cc
up to 60 (I 5) dg/minHigh Flow, High Gloss & Low
warpage Injection Moulding Grades
High Flow, High Gloss & Low
warpage Injection Moulding Grades
Good balance of ESCR, Stiffness
& impact properties in
blow moulding grades
Good balance of ESCR, Stiffness
& impact properties in
blow moulding grades
Good processability & low water carry over in Raffia
Grades
Good processability & low water carry over in Raffia
Grades
Excellent Dart Impact & Sealing
Properties in Film Grades
Excellent Dart Impact & Sealing
Properties in Film GradesExcellent
combination of processability &
final product performance in bimodal grades
Excellent combination of processability &
final product performance in bimodal grades
Technology : Hostalen
Licensor : Basell
Capacity : 300 KTA
Product : HDPE
IOCL HDPE (Hostalen Plant) : Product EnvelopeD
ens
ity
(g/c
c)
INJECTION
MOULDING*
0.97
18.02.001.201.000.22 0.280.10
0.95
0.94
0.93
0.96
PIPES
LARGE CONTAINERS
TAPES & MONOFILAMENT *
MFI I5 (g/10 min)
* MFI I2 (g/10 min)
HM FILM
SMALL BOTTLES
MFI (g/10 min)
0.1
1
10
100
0.91 0.92 0.93 0.94 0.95 0.96 0.97
Density (g/cc)
MF
I (g
/10
min
)
LL IM
EX. COATING
PIPE COATING
HD IM
ROTO MOLDING
LL FILM
W&CRAFFIA
PIPE/ PIPE COATING/
HD FILM/ BM
IOCL PE (Swing Plant) : Product Envelope
Technology :Sclairtech
Licensor : Nova Chemicals
Plant capacity : 350 KTA
Product : LLDPE/ HDPE
IOCL GRADE
IOCL HDPE (Swing Plant) : Product Attributes
Road Map
Objective: To demonstrate Polyolefin Geosynthetics as an essential and important material for roads and infrastructure projects for for long lasting performance and cost benefits.
Break up of Activities
IOCL PE (Swing Plant) : Product Envelope
Types Denier Functions
Tapes 1650 -1700 Reinforcement, Embankment, Separation
FDY 840x1200 Reinforcement, Embankment, Separation
Staple Fiber 3 Filtration, Separation
Typical PP Woven Geotextiles
Property Sample 1 Sample 2 Sample 3
Mass per unit area [gsm] 250 220 180
Thickness [mm] 3.0 2.5 1.8
Apparent Opening Size [mm] 0.60 0.60 0.60
Grab tensile strength [kN] 3.0 2.5 2.0
Wide with tensile strength [kN/m]
Warp
Weft
90
85
70
65
55
50
Trapezoidal tear strength [kN] 1.5 1.2 0.75
Puncture resistance [kN] 0.90 0.75 0.60
UV resistance [ % 500 hr exposure] 50 - 70 50 -70 50 - 70Samples Wide width tensile
strength [kN/m]Mass per unit
area [gsm]Thickness
[mm]Thread count [per
inch]
Warp Weft Warp Weft
Sample 1 90 85 250 3.0 20 18
Sample 2 70 65 220 2.5 15 14
Sample 3 55 50 180 1.8 12 11
Specifications for Polypropylene Woven Geotextiles for use in Road/ Pavement Reinforcement
Sr. No Particulars Values1 Material 100%-polypropylene2 EOS as per site3 Sp.gravity 0.914 Weight in Grms per sq.mtr >2105 Thickness in MM >0.596 Breaking strength
(5cm x 20 cm strip) (IS:1969-LATEST ADITION) Warp way (kgs) >215 Weftway (kgs) >155
7 Elongation (IS:1969-LATEST ADITION) warp way <36 weft way <33
8 Grab strength (3"x1" strip) (ASTM D1682) warpway (kgs) >182 weftway (kgs) >130
9 Elongation % (grab test) (ASTM D1682) Warpway <36 Weftway <33
10 Tear strength (single) (ASTM D1682) warpway (kgs) >41 weftway (kgs) >44
11 Water permeability- (litres/cm/sq mtr) at 10 cm.water head >10
12 width of fabric >2.0 mtrs
Non-Woven Geotextile standards
S.No Property Test Method Values
1 Polymer PP/PE/PET/Polyamide
2 Mass/Area IS: 14716 /ASTM D: 3776
250 GSM minimum
3 Thickness at 2 Kpa ASTM: 5199 2 mm (minimum)
4 Roll width 5.0 metre (minimum)
5 Roll Length 50 m (minimum)
Mechanical Properties
1 Tensile Strength IS: 13162 / ASTM D4595 /EN ISO: 10319
40kN/m (Minimum)
2 Elongation at Break IS: 13162 /ASTM D 4595 /EN ISO: 10319
40 % - 70%
Hydraulic Properties
1 Apparent opening size O95 IS 14294 /ASTM D: 4751 /EN ISO: 12956
40 – 85 microns
2 Water Flow Rate the Plane IS: 14324/ASTM D: 4491
20 lit. /m2/s(minimum)
Woven Geotextile standards
S.No
Property Test Method Values
1 Polymer PP/PE/PET/Polyamide2 Mass/Area IS: 14716 /
ASTM D: 3776100GSM minimum
3 Thickness at 2 Kpa ASTM: 5199 0.65 mm (minimum)4 Roll width 5.0 metre (minimum)
5 Roll Length 50 m (minimum)
Mechanical Properties1 TS at Warp IS: 1969 /
ASTM D 4595 /EN ISO: 10319
40kN/m (Minimum)TS at Weft 35kN/m (Minimum)
2 Elongation at Warp IS: 1969 /ASTM D 4595 /EN ISO: 10319
15%-30 %
Elongation at Warp 15%-30 %
3 Puncture Strength Puncture Strength IS: 13162 /ASTM D: 4833
600 N (Minimum)
Hydraulic Properties1 Apparent opening size O95 IS 14294 /
ASTM D: 4751 /EN ISO: 12956
425 microns(maximum)
2 Water Flow Rate the Plane IS: 14324/ASTM D: 4491
15 lit. /m2/s(minimum)
IOCL PE (Swing Plant) : Product Envelope
Woven monofilament Calendared
Multifilament Slit Film (Tape x Tape)
Needle – Punched Thermal Bonded