feasibility report -...

FEASIBILITY REPORT

FOR

100% BS-V AUTO FUEL PRODUCTION AT 13.7 MMTPA

INDIAN OIL CORPORATION LIMITED GUJRAT REFINERY

JANUARY -2016

FEASIBILITY REPORT

FOR

100% BS-V AUTO FUEL PRODUCTION AT 13.7 MMTPA

CLIENT INDIAN OIL CORPORATION LIMITED

GUJRAT REFINERY

PREPARED BY ENGINEERS INDIA LIMITED

NEW DELHI

EIL JOB No.: A510

REPORT No. A510-RP-7941-0002 VOLUME 1 OF 1 JANUARY 2016

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

Document No. A510-RP-7941-0002

Rev. No. 1

Page 2 of 264

FEASIBILITY REPORT FOR 100% BS-V AUTO FUEL PRODUCTION

AT 13.7 MMTPA

FOR IOCL GUJARAT REFINERY

COPYRIGHT

This document is copyright protected by EIL and is produced for the client M/S IOCL. Neither of this document or any extract from it may be produced, stored or transmitted in any form for any purpose by any party without prior written permission from EIL. Request for additional copies or permission to reproduce any part of document for any commercial purpose should be addressed as shown below: General Manager (Process-2) Tower-II, 5th Floor Engineers India Limited Complex Sector-16 Gurgaon- 122001 Haryana (India) Telephone: 0124-380-3701 EIL reserves the right to initiate appropriate legal action against any unauthorized use of its Intellectual Property by any entity.



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TABLE OF CONTENTS

SECTION CONTENT

1. EXECUTIVE SUMMARY

2. INTRODUCTION

3. SCOPE

4. DESIGN BASIS

5. MARKET STUDY

6. PROJECT LOCATION

7. PROJECT DESCRIPTION

7.1 PROJECT CONFIGURATION

7.2 REFINERY CONFIGURATION STUDY

7.3 PROCESS DESCRIPTION

7.4 MATERIAL BALANCE

7.5 UTILITIES DESCRIPTION

7.6 OFFSITES DESCRIPTION

7.7 FLARE SYSTEM DESCRIPTION

8. ENVIRONMENTAL CONSDIERATION

9. PROJECT IMPLEMENTATION AND SCHEDULE

10. PROJECT COST ESTIMATE

11. FINANCIAL ANALYSIS

12. HEALTH SAFETY & ENVIRONMENT

13. CONCLUSION & RECOMMENDATIONS

ANNEXURES

I CRUDE ASSAYS

II BLOCK FLOW DIAGRAMS

III SCHEMATIC DIAGRAMS

IV PLOT PLAN



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SECTION 1.0

EXECUTIVE SUMMARY



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1.0 EXECUTIVE SUMMARY

1.1 Introduction

Indian Oil Corporation Limited (IOCL) operates one of its largest oil refineries at Koyali (near Vadodara) in Gujarat, Western India. The refinery was commissioned in the year 1965 with a nameplate capacity of 3.0 MMTPA. Over the years, the capacity of the refinery has gradually been increased to 13.7 MMTPA with augmentation of old primary Atmospheric Units (AU-I, AU-II and AU-III) and addition of new primary units viz. Atmospheric Unit-IV in 1978 and AU-V in 1999 as well as augmentation of AU-IV in 2000.

Secondary processing facilities viz. Fluidized Catalytic Cracking Unit (FCCU)and Hydro-cracking Unit (HCU) were added in the years 1982 and 1993 respectively to improve the distillate yield. Diesel Hydro-desulphurization Unit (DHDS) and Hydrogen Generation Unit (HGU) were added in 1999 to meet BS-2000/BS-II quality of HSD. MS Quality Improvement Project comprising of Continuous Catalytic Reforming Unit (CCRU) and revamp of DHDS were carried out in the years 2006 and 2007 respectively to meet BS-II/BS-III MS and HSD quality respectively.

Further, under the Residue Upgradation Project (RUP) and MS/HSD quality improvement Project Delayed Coking Unit (DCU), Vacuum Gas oil Hydro-Treater Unit (VGO-HDT), Diesel HydrotreaterUnit (DHDT), Hydrogen Generation Unit-III (HGU-III), Sulphur Recovery Unit(SRU), Isomerisation Unit (ISOM), ATF & LPG Merox units were commissioned in 2010-11.

At present, Gujarat Refinery has capacity to process 13.7 MMTPA of crude oil, with crude basket comprising of 55% high sulphur crude (7.6 MMTPA) and 45% low sulphur indigenous crude (6.1 MMTPA).In addition to BS-III/BS-IV fuel products, the refinery also has the capability to produce a wide range of specialty products such as benzene, toluene, MTBE, MTO, Food Grade Hexane & LAB.

In current refinery operations, refinery produces Gasoline and Diesel conforming to BS-III & BS-IV specifications. Currently refinery is executing projects to upgrade the entire gasoline and diesel to BS-IV specification by revamp of existing DHDT, DHDS and VGO hydrotreater units.

With objective of meeting the guidelines established in Auto Fuel Policy 2025, wherein refinery would be required to manufacture 100% BS-V fuels. IOCL has entrusted M/s Engineers India Limited to carry out the job of assessment of the configuration and modification/additional facilities required to comply to BS-V auto fuel specification for the existing crude processing capacity of 13.7 MMTPA and preparation of feasibility report with a cost estimate of ± 30%. This report documents the results of the study.

1.2 Objectives

The major objectives of the study are to:

Develop refinery configuration for the production of 100% BS-V products at the existing refining capacity of 13.7 MMTPA.



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Assessment of additional facilities required to comply to BS V auto fuel specification for 13.7 MMTPA crude processing capacity.

Estimate capital cost with an accuracy of ± 30%.

1.3 Basis of Configuration Study

1.3.1 Refinery Throughput

13.7 MMTPA

1.3.2 Crude Mix

The configuration study has been carried out for the design crude mix as per the table below:

Table 1.3.1: Crude Mix

CRUDE TYPE MMTPA

North Gujarat (NG) 3.7

South Gujarat (SG) 1.7

Rajasthan Crude 0.8

Kuwait 7.5

1.3.3 Crude Assay

The crude assays utilized for the study are attached in Annexure-1.

1.3.4 Refinery On-Stream Hours

8000 hrs/annum.

1.3.5 Feed and Product Prices

The feed and product prices considered for base case and 100% BS-V case with MSQU and ISOM unit revamp is provided below in table 1.3.2A & B. The prices are based on average prices during FY 2011-14.

Table 1.3.2A Feed Prices (Rs/MT)

CRUDE 3 YEAR AVERAGE

North Gujarat (NG) 41373

South Gujarat (SG) 46327

Rajasthan Crude 40266

Kuwait 42089

LNG/RLNG 44524



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Methanol 29557

Benzene 57859

Table 1.3.2B Product Prices (Rs/MT)

PRODUCT 3 YEAR AVERAGE

LPG 50059

Naphtha Export 50595

Food Grade Hexane 73277

MS BS-V (Normal grade) 58510

HY. REFORMATE TO IOCL GR

50595

SKO 54866

PCK NA

ATF 54955

LAB 61025

HSDBS-V 53826

Bitumen 60/70 32962

HS Coke 5050

Fuel Oil -Regular 37737

Fuel Oil –Low Sulphur 37617

Fuel Oil - High Sulphur 37737

Sulphur 8835

1.3.6 Product Specifications

The diesel and gasoline fuels produced from refinery after implementation of the project shall conform to BS-V specifications. The major specifications of products shall be:

Regular grade BS-V Gasoline ( 91 RON)**-10ppmw sulphur*

Premium grade BS-V Gasoline (95 RON)***- 10ppmw sulphur*

Diesel BS-V: 10 ppmw Sulfur*

* Manufacturing spec. of 8 ppm has been considered.

** Manufacturing spec. of 91.2 has been considered.

***Manufacturing spec. of 95.5 has been considered.

1.3.7 Production Limits

The limits on various products have been considered as per Table 1.3.3 below:



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Table 1.3.3: Production Limits (KTPA)

PRODUCT MAXIMUM

QUANTITY (KTPA) FIXED QUANTITY

(KTPA)

Naphtha (As produced)

-

Total Gasoline 1600 -

SKO 500 Max -

ATF 400 Max -

MTO Nil -

LDO Nil -

Bitumen 630 -

Fuel Oil Sales - High Sulphur 30

Fuel Oil Sales - Low Sulphur 210

Fuel Oil Sales- Regular grade 160

1.3.8 Other Constraints & Considerations

The base case shall be considered with BS-IV auto fuel compliance considering the revamp of existing DHDT, DHDS and VGO-HDT units.

In a separate study carried out internally by IOCL, it has been established that the existing CCR and ISOM units can be revamped by 30% and 20% respectively. Thus higher gasoline potential to be considered with revamp as advised by IOCL. This will increase the production of gasoline beyond 1600 KTPA meeting BS-V specification.

With the revamp of existing MSQU and ISOM units the potential of producing premium grade gasoline from the refinery has been considered.

Kerosene production to be reduced by upgrading kero streams to diesel product

1.3.9 Plant Fuel System

RLNG has been considered as fuel for the following facilities in the 100% BS-V configuration.

Existing GT’s+HRSG.

Feed/Fuel to existing HGU-III and new HGU.

Fuel to Existing HGU-1

Internally generated Fuel Oil (Sul<0.5 wt %) and fuel gas have been considered as fuel for refinery furnaces.



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1.4 Configuration study approach

Development of Base LP model of refinery to produce 100% BS-IV products for the existing capacity of 13.7 MMTPA based on the IOCL input data.

While going for production of BS-V gasoline and diesel production from BS-IV products, the main objective is the reduction of sulphur specification in the blend components. Hence a new DHDT unit has been considered for treating BS-IV diesel components having high sulphur specification.

Carry out further analysis to blend maximum possible kero components into diesel product by reducing their sulphur spec in the new DHDT unit considered.

Similarly for meeting BS-V sulphur specification in gasoline product pool, consider a FCC gasoline desulphurization unit for treating high sulphur FCC gasoline components from FCC.

As advised by IOCL consideration of revamp of MSQU, and ISOM units to maximize the gasoline production meeting BS-V specification and also producing 240 KTPA of premium grade gasoline.

1.5 Configuration results for 100% BS-V with MSQU and ISOM revamp

A new DHDT unit of capacity 1500 KTPA is considered to produce 100% BS-V Diesel.

A FCC gasoline desulphurization unit is required to remove sulphur from FCC gasoline stream to meet BS-V spec. The unit shall be designed for a capacity of 700 KTPA.

An incremental Hydrogen Generation capacity of 40 KTPA is required to meet the additional consumption in the refinery. However as advised by IOCL a Hydrogen Generation Unit of capacity 72.5 KTPA shall be considered, which may also meet any future requirements of expansion.

In addition to 100% BS-V gasoline and diesel production, 30% revamp of MSQU and 20% revamp of ISOM units have been considered as part of the study to upgrade naphtha product to gasoline meeting BS-V specification. This also gives opportunity to produce 240 KTPA of premium grade gasoline.

Additionally following auxiliary units have been considered as part of this project:

a) A new SWS unit of capacity 55 TPH to process incremental sour water produced in new/ revamped process units.

b) A new Amine Recovery unit of 190 TPH capacity, considering that the new DHDT unit under BS-V project may process high sulphur feed in future.



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c) Since there is no substantial increase in overall sulphur production in refinery after BS-V project, no new SRU is envisaged.

1.6 Material Balance

Table 1.5.1 below provides the material balance for both cases considered for 100% BS-V production with MSQU and ISOM unit revamp. Base case values have been provided for comparison.

Table 1.6.1: Overall material balance

Sl. No

Streams 100% BS-V Case (No Premium gasoline)

100% BS-V Case (With Premium gasoline)

Base Case (KTPA)

Feed

1 North Gujarat crude 3700 3700 3700

2 South Gujarat crude 1700 1700 1700

3 Mangla crude 800 800 800

4 Kuwait crude 7500 7500 7500

Total Crude 13700 13700 13700

5 Benzene Import 18 18 18

6 Methanol 11 11 11

7 RLNG import 696 696 562

Total feed 14425 14425 14291

Products

1 LPG 499.7 499.7 494

2 Export Naphtha 944 971 1169

3 LAB 120 120 120

4 FGH 14 14 14

5 Gasoline- Normal grade (BS-IV)

0 0 1565

6 Gasoline- Normal grade (BS-V)

1899 1631.7 0

7 Gasoline- Premium grade (BS-V)

0 240 0

8 Heavy reformate to IOCL Guwahati refinery

60 60 60

9 Kerosene 500 500 1000

10 ATF 400 400 400

11 PCK 70 70 70



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Sl. No



Base Case (KTPA)

12 HSD (BS-IV) 0 0 6434

13 HSD (BS-V) 6827 6827 0

14 Bitumen 430.7 430.7 430

15 Coke 663 663 663

16 Fuel Oil sales- regular grade

160 160 160

17 Fuel Oil sales- Low sulphur

218 218 218

18 Fuel Oil sales - High sulphur

30 30 30

19 Sulphur 102 102 101.4

20 Fuel & loss (Including FCC coke)

1487 (10.85 wt% on total crude)



Total Products 14425 14425 14291

1.7 Utility Systems Following new Utility systems shall be implemented along with the new process units. These are after considering integration & centralization with existing utility system.

Table 1.6.2: New Utility systems

UTILITY SYSTEM

DESCRIPTION

Raw water system The incremental requirement of 140 m3 of raw water from additional facilities shall be made available from the existing facilities.

Recirculating Cooling water

A new cooling tower cell and cooling water pump of 4000 m3/hr capacity each is to be added with North Block Cooling Tower.

A new cooling tower cell and cooling water pump of 4000 m3/hr capacity each is to be added with South Block Cooling Tower

DM Water Additional requirement of 65 m3 of DM water shall be made available from the existing facilities.



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UTILITY SYSTEM

DESCRIPTION

Steam Additional net requirement of 20TPH shall be made available from the existing facilities.

Power Additional requirement of 13.5 MW power shall be made available from the existing facilities.

Condensate handling A new Condensate Polishing Unit with a capacity of 30 TPH (1W+1S)

Internal Fuel Oil and Fuel gas Additional requirement of 1500 Nm3/hr of fuel gas shall be made available from the existing facilities.

Compressed Air System

Additional 1500 Nm3/hr of instrument air shall be required for additional facilities envisaged under BS-V project. To meet this requirement a new Instrument Air dryer of 5000 nm3/hr and associated facility is envisaged.

Nitrogen Additional requirement of 160 Nm3/hr of Nitrogen for additional facilities shall be made available from the existing facilities.

1.8 Offsite System

The offsite facilities of the refinery shall be augmented by adding a new storage tank and pump.

Table 1.8.1A: New storage tanks Sl. No

Service No of Tanks

Type Liquid stored capacity of each tank (kL)

1

New DHDT/FCC Gasoline Desulphurization Unit intermittent feed storage

1 Floating roof

20,000

Table 1.8.1B: New pump Sl. No

Service No of

pumps Flow

(m3/hr) Type

1 New DHDT Unit / FCC Gasoline Desulphurization Unit feed pumps

1W+1S 250 Centrifugal Motor driven



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1.9 Flare System A new flare system is envisaged as a part of this project in place of existing flare as advised by IOCL, to handle the load of existing refinery, incremental load due to revamp of units for 100% BS-IV and incremental loads due to new units for 100% BS-V production. The stack diameter of new flare shall be 84”.

1.10 Conclusion With a new DHDT, FCC gasoline desulphurization unit and a new Hydrogen Generation Unit along with revamps of existing MSQU and Isomerization units, the refinery shall be able to produce all gasoline and diesel products conforming to BS-V specifications at 13.7 MMTPA capacity along with enhanced production of gasoline and diesel while reducing production of naphtha and Kerosene as compared to existing product slate. The total cost for new facilities under 100% BS-V auto fuel production project has been estimated as 2502.61 Crores.



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1.0 EXECUTIVE SUMMARY

1.1 Introduction

Indian Oil Corporation Limited (IOCL) operates one of its largest oil refineries at Koyali (near Vadodara) in Gujarat, Western India. The refinery was commissioned in the year 1965 with a nameplate capacity of 3.0 MMTPA. Over the years, the capacity of the refinery has gradually been increased to 13.7 MMTPA with augmentation of old primary Atmospheric Units (AU-I, AU-II and AU-III) and addition of new primary units viz. Atmospheric Unit-IV in 1978 and AU-V in 1999 as well as augmentation of AU-IV in 2000.

Secondary processing facilities viz. Fluidized Catalytic Cracking Unit (FCCU)and Hydro-cracking Unit (HCU) were added in the years 1982 and 1993 respectively to improve the distillate yield. Diesel Hydro-desulphurization Unit (DHDS) and Hydrogen Generation Unit (HGU) were added in 1999 to meet BS-2000/BS-II quality of HSD. MS Quality Improvement Project comprising of Continuous Catalytic Reforming Unit (CCRU) and revamp of DHDS were carried out in the years 2006 and 2007 respectively to meet BS-II/BS-III MS and HSD quality respectively.

Further, under the Residue Upgradation Project (RUP) and MS/HSD quality improvement Project Delayed Coking Unit (DCU), Vacuum Gas oil Hydro-Treater Unit (VGO-HDT), Diesel HydrotreaterUnit (DHDT), Hydrogen Generation Unit-III (HGU-III), Sulphur Recovery Unit(SRU), Isomerisation Unit (ISOM), ATF & LPG Merox units were commissioned in 2010-11.

At present, Gujarat Refinery has capacity to process 13.7 MMTPA of crude oil, with crude basket comprising of 55% high sulphur crude (7.6 MMTPA) and 45% low sulphur indigenous crude (6.1 MMTPA).In addition to BS-III/BS-IV fuel products, the refinery also has the capability to produce a wide range of specialty products such as benzene, toluene, MTBE, MTO, Food Grade Hexane & LAB.

In current refinery operations, refinery produces Gasoline and Diesel conforming to BS-III & BS-IV specifications. Currently refinery is executing projects to upgrade the entire gasoline and diesel to BS-IV specification by revamp of existing DHDT, DHDS and VGO hydrotreater units.

With objective of meeting the guidelines established in Auto Fuel Policy 2025, wherein refinery would be required to manufacture 100% BS-V fuels. IOCL has entrusted M/s Engineers India Limited to carry out the job of assessment of the configuration and modification/additional facilities required to comply to BS-V auto fuel specification for the existing crude processing capacity of 13.7 MMTPA and preparation of feasibility report with a cost estimate of ± 30%. This report documents the results of the study.

1.2 Objectives

The major objectives of the study are to:

· Develop refinery configuration for the production of 100% BS-V products at the existing refining capacity of 13.7 MMTPA.



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· Assessment of additional facilities required to comply to BS V auto fuel specification for 13.7 MMTPA crude processing capacity.

· Estimate capital cost with an accuracy of ± 30%.

1.3 Basis of Configuration Study

1.3.1 Refinery Throughput

13.7 MMTPA

1.3.2 Crude Mix

The configuration study has been carried out for the design crude mix as per the table below:

Table 1.3.1: Crude Mix

CRUDE TYPE MMTPA

North Gujarat (NG) 3.7

South Gujarat (SG) 1.7

Rajasthan Crude 0.8

Kuwait 7.5

1.3.3 Crude Assay

The crude assays utilized for the study are attached in Annexure-1.

1.3.4 Refinery On-Stream Hours

8000 hrs/annum.

1.3.5 Feed and Product Prices

The feed and product prices considered for base case and 100% BS-V case with MSQU and ISOM unit revamp is provided below in table 1.3.2A & B. The prices are based on average prices during FY 2011-14.

Table 1.3.2A Feed Prices (Rs/MT)

CRUDE 3 YEAR AVERAGE

North Gujarat (NG) 41373

South Gujarat (SG) 46327

Rajasthan Crude 40266

Kuwait 42089

LNG/RLNG 44524



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Methanol 29557

Benzene 57859

Table 1.3.2B Product Prices (Rs/MT)

PRODUCT 3 YEAR AVERAGE

LPG 50059

Naphtha Export 50595

Food Grade Hexane 73277

MS BS-V (Normal grade) 58510

HY. REFORMATE TO IOCL GR

50595

SKO 54866

PCK NA

ATF 54955

LAB 61025

HSDBS-V 53826

Bitumen 60/70 32962

HS Coke 5050

Fuel Oil -Regular 37737

Fuel Oil –Low Sulphur 37617

Fuel Oil - High Sulphur 37737

Sulphur 8835

1.3.6 Product Specifications

The diesel and gasoline fuels produced from refinery after implementation of the project shall conform to BS-V specifications. The major specifications of products shall be:

· Regular grade BS-V Gasoline ( 91 RON)**-10ppmw sulphur*

· Premium grade BS-V Gasoline (95 RON)***- 10ppmw sulphur*

· Diesel BS-V: 10 ppmw Sulfur*

* Manufacturing spec. of 8 ppm has been considered.

** Manufacturing spec. of 91.2 has been considered.

***Manufacturing spec. of 95.5 has been considered.

1.3.7 Production Limits

The limits on various products have been considered as per Table 1.3.3 below:



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Table 1.3.3: Production Limits (KTPA)

PRODUCT MAXIMUM

QUANTITY (KTPA)

FIXED QUANTITY

(KTPA)

Naphtha (As produced)

-

Total Gasoline 1600 -

SKO 500 Max -

ATF 400 Max -

MTO Nil -

LDO Nil -

Bitumen 630 -

Fuel Oil Sales - High Sulphur 30

Fuel Oil Sales - Low Sulphur 210

Fuel Oil Sales- Regular grade 160

1.3.8 Other Constraints & Considerations

· The base case shall be considered with BS-IV auto fuel compliance considering the revamp of existing DHDT, DHDS and VGO-HDT units.

· In a separate study carried out internally by IOCL, it has been established that the existing CCR and ISOM units can be revamped by 30% and 20% respectively. Thus higher gasoline potential to be considered with revamp as advised by IOCL. This will increase the production of gasoline beyond 1600 KTPA meeting BS-V specification.

· With the revamp of existing MSQU and ISOM units the potential of producing premium grade gasoline from the refinery has been considered.

· Kerosene production to be reduced by upgrading kero streams to diesel product

1.3.9 Plant Fuel System

RLNG has been considered as fuel for the following facilities in the 100% BS-V configuration.

· Existing GT’s+HRSG.

· Feed/Fuel to existing HGU-III and new HGU.

· Fuel to Existing HGU-1

Internally generated Fuel Oil (Sul<0.5 wt %) and fuel gas have been considered as fuel for refinery furnaces.



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1.4 Configuration study approach

· Development of Base LP model of refinery to produce 100% BS-IV products for the existing capacity of 13.7 MMTPA based on the IOCL input data.

· While going for production of BS-V gasoline and diesel production from BS-IV products, the main objective is the reduction of sulphur specification in the blend components. Hence a new DHDT unit has been considered for treating BS-IV diesel components having high sulphur specification.

· Carry out further analysis to blend maximum possible kero components into diesel product by reducing their sulphur spec in the new DHDT unit considered.

· Similarly for meeting BS-V sulphur specification in gasoline product pool, consider a FCC gasoline desulphurization unit for treating high sulphur FCC gasoline components from FCC.

· As advised by IOCL consideration of revamp of MSQU, and ISOM units to maximize the gasoline production meeting BS-V specification and also producing 240 KTPA of premium grade gasoline.

1.5 Configuration results for 100% BS-V with MSQU and ISOM revamp

· A new DHDT unit of capacity 1500 KTPA is considered to produce 100% BS-V Diesel.

· A FCC gasoline desulphurization unit is required to remove sulphur from FCC gasoline stream to meet BS-V spec. The unit shall be designed for a capacity of 700 KTPA.

· An incremental Hydrogen Generation capacity of 40 KTPA is required to meet the additional consumption in the refinery. However as advised by IOCL a Hydrogen Generation Unit of capacity 72.5 KTPA shall be considered, which may also meet any future requirements of expansion.

· In addition to 100% BS-V gasoline and diesel production, 30% revamp of MSQU and 20% revamp of ISOM units have been considered as part of the study to upgrade naphtha product to gasoline meeting BS-V specification. This also gives opportunity to produce 240 KTPA of premium grade gasoline.

· Additionally following auxiliary units have been considered as part of this project:

a) A new SWS unit of capacity 55 TPH to process incremental sour water produced in new/ revamped process units.

b) A new Amine Recovery unit of 190 TPH capacity, considering that the new DHDT unit under BS-V project may process high sulphur feed in future.



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c) Since there is no substantial increase in overall sulphur production in refinery after BS-V project, no new SRU is envisaged.

1.6 Material Balance

Table 1.5.1 below provides the material balance for both cases considered for 100% BS-V production with MSQU and ISOM unit revamp. Base case values have been provided for comparison.

Table 1.6.1: Overall material balance

Sl. No



Base Case (KTPA)

Feed

1 North Gujarat crude 3700 3700 3700

2 South Gujarat crude 1700 1700 1700

3 Mangla crude 800 800 800

4 Kuwait crude 7500 7500 7500

Total Crude 13700 13700 13700

5 Benzene Import 18 18 18

6 Methanol 11 11 11

7 RLNG import 696 696 562

Total feed 14425 14425 14291

Products

1 LPG 499.7 499.7 494

2 Export Naphtha 944 971 1169

3 LAB 120 120 120

4 FGH 14 14 14

5 Gasoline- Normal grade (BS-IV)

0 0 1565

6 Gasoline- Normal grade (BS-V)

1899 1631.7 0

7 Gasoline- Premium grade (BS-V)

0 240 0

8 Heavy reformate to IOCL Guwahati refinery

60 60 60

9 Kerosene 500 500 1000

10 ATF 400 400 400

11 PCK 70 70 70



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Sl. No



Base Case (KTPA)

12 HSD (BS-IV) 0 0 6434

13 HSD (BS-V) 6827 6827 0

14 Bitumen 430.7 430.7 430

15 Coke 663 663 663

16 Fuel Oil sales- regular grade

160 160 160

17 Fuel Oil sales- Low sulphur

218 218 218

18 Fuel Oil sales - High sulphur

30 30 30

19 Sulphur 102 102 101.4

20 Fuel & loss (Including FCC coke)




Total Products 14425 14425 14291

1.7 Utility Systems Following new Utility systems shall be implemented along with the new process units. These are after considering integration & centralization with existing utility system.

Table 1.6.2: New Utility systems

UTILITY SYSTEM

DESCRIPTION

Raw water system The incremental requirement of 140 m3 of raw water from additional facilities shall be made available from the existing facilities.

Recirculating Cooling water

· A new cooling tower cell and cooling water pump of 4000 m3/hr capacity each is to be added with North Block Cooling Tower.

· A new cooling tower cell and cooling water pump of 4000 m3/hr capacity each is to be added with South Block Cooling Tower

DM Water Additional requirement of 65 m3 of DM water shall be made available from the existing facilities.



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UTILITY SYSTEM

DESCRIPTION

Steam Additional net requirement of 20TPH shall be made available from the existing facilities.

Power Additional requirement of 13.5 MW power shall be made available from the existing facilities.

Condensate handling A new Condensate Polishing Unit with a capacity of 30 TPH (1W+1S)

Internal Fuel Oil and Fuel gas Additional requirement of 1500 Nm3/hr of fuel gas shall be made available from the existing facilities.

Compressed Air System

Additional 1500 Nm3/hr of instrument air shall be required for additional facilities envisaged under BS-V project. To meet this requirement a new Instrument Air dryer of 5000 nm3/hr and associated facility is envisaged.

Nitrogen Additional requirement of 160 Nm3/hr of Nitrogen for additional facilities shall be made available from the existing facilities.

1.8 Offsite System

The offsite facilities of the refinery shall be augmented by adding a new storage tank and pump.

Table 1.8.1A: New storage tanks Sl.

No Service

No of

Tanks

Type Liquid stored capacity

of each tank (kL)

1

New DHDT/FCC Gasoline Desulphurization Unit intermittent feed storage

1 Floating roof

20,000

Table 1.8.1B: New pump Sl.

No Service

No of

pumps

Flow

(m3/hr)

Type

1

New DHDT Unit / FCC Gasoline Desulphurization Unit feed pumps

1W+1S 250 Centrifugal Motor driven



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AT 13.7 MMTPA


1.9 Flare System A new flare system is envisaged as a part of this project in place of existing flare as advised by IOCL, to handle the load of existing refinery, incremental load due to revamp of units for 100% BS-IV and incremental loads due to new units for 100% BS-V production. The stack diameter of new flare shall be 84”.

1.10 Conclusion With a new DHDT, FCC gasoline desulphurization unit and a new Hydrogen Generation Unit along with revamps of existing MSQU and Isomerization units, the refinery shall be able to produce all gasoline and diesel products conforming to BS-V specifications at 13.7 MMTPA capacity along with enhanced production of gasoline and diesel while reducing production of naphtha and Kerosene as compared to existing product slate. The total cost for new facilities under 100% BS-V auto fuel production project has been estimated as 2502.61 Crores.

Other details: EFFLUENT GENERATION & DISPOSAL: Our entire plant area is paved and all contaminated discharges will be routed to existing ETP system of 1500 m3/hr capacity, or CBD (closed blow down system) for treatment / recycle. The treated effluent will be recycled. Also during normal operation sour water and rich amine are the liquid effluent ex Hydrotreating unit. To process liquid effluent ex new Hydrotreating units a new Amine Regeneration Unit(ARU) shall be installed. Incremental effluent generation of 50-100 m3/hr is envisaged from this project. SOx EMISSION CONTROL: Incremental Sox emission due to BS-VI project of 115-125 kg/hr is envisaged .Total limit of SOx emission from the entire refinery complex post BS-VI project at the current level of 940 Kg/Hr. SOLID WASTE : Solid wastes will be disposed to our existing earmarked area. ********************************************************************

O&m

Room

High

Mass

High

Mass

High

Mass

High

Mass

High

Mass

High

Mass

Co

nve

yo

r B

elt

Ca

ble

T

re

nch

Ca

ble

T

re

nch

Ca

ble

T

re

nch

Calico Area

T

r

a

c

k

N

o

. 0

1

Track N

o. 0

9

Tra

ck N

o. 1

7

Tra

ck N

o. 1

6

Tra

ck N

o. 1

4

Tra

ck N

o. 1

3

Track N

o. 12

Tra

ck N

o. 1

1

Tra

ck N

o. 10

Tra

ck N

o. 0

9

Tra

ck N

o. 0

8

Tra

ck N

o. 0

7

Tra

ck N

o. 0

6

Tra

ck N

o. 0

5

Tra

ck N

o. 0

4

Tra

ck N

o. 0

3

Tra

ck N

o. 0

2

Tra

ck N

o. 1

6

Tra

ck N

o. 1

5

Tra

ck N

o. 1

4

Track N

o. 13

Tra

ck N

o. 1

2

Tra

ck N

o. 1

1

Tra

ck N

o. 1

0

Tra

ck N

o. 0

8

Tra

ck N

o. 0

7

Tra

ck N

o. 1

7

Tra

ck N

o. 0

6

Tra

ck N

o. 0

5

Tra

ck N

o. 0

4

Tra

ck N

o. 0

3

Track N

o. 02

Dra

in

Drain

Drain

Drain

Drain

Drain

Drain

Drain

RoadNo. 02

RoadNo. 02

Road No. 02

Road N

o. 01

Road N

o. 01

Road N

o. 01

Road No. 24

Road N

o. 21

Road N

o. 23

Road N

o.11

Road N

o.11

Road N

o.11

Road N

o.11

Road N

o.3

Road N

o.3

Road N

o.3

R

o

a

d

N

o

.

0

9

Road N

o. 5

Road N

o. 01

Ro

ad

N

o. 0

1R

oad N

o. 01

Road N

o. 01

Road N

o. 01

Road No. 22Road No. 22

Road N

o. 23a

Road N

o. 23a

Road N

o. 05

Road N

o. 05

Road No. 12

Road N

o.07

Road N

o. 09

Road N

o. 05a

Road N

o. 05

Road N

o. 03

Road N

o. 01

Road N

o. 11a

Road N

o.13

Ro

ad

N

o.1

3aR

oad N

o.15

Road No.08

Road N

o. 09

R

o

a

d

N

o

.

3

0

Ca

ble

T

re

nch

Store

Shed

LPG Mounded

Bullets

CO

KE

Y

AR

D

PIL

E (H

IG

H S

UL

PH

UR

)

Gate N

o.2

Op

en

D

ra

in

Open Drain

T

o

T

o

w

n

s

h

i

p

G

r

e

e

n

B

e

l

t

A

r

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a

G

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B

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A

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a

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D

r

a

in

R

o

a

d

C

o

m

p

o

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n

d

W

a

l

l

Open Drain

Pipe Corridor

New Flare Stack

Road

C

o

m

p

o

u

n

d

W

a

ll

O

pen C

hannal

Plate Farm

Railyay Track

Conveyor Belt

Pond

Canteen

Marketing Division

Bitumen

Filling Station

W-T

ESS No.18

No

rth

B

lo

ck

ES

S N

o.1

8A

Tk.1513

Tk.1505

Tk.1512

Tk.1510

Tk.1511

Tk.775

Tk.748

Tk.747

Tk.746

Tk.745

Tk.744

Tk.743

Tk.742

Tk.741

Tk.713

Tk.714

Tk.712Tk.711 Tk.718

Tk.715

Tk.717

Tk.718Tk.739

Tk.738

Tk.729

Tk.727 Tk.728

Tk.730

Tk.723Tk.724

Tk.725

Tk.726

O.N.G.C.

Tk.520

Tk.519

Tk.522

Tk.1517

Tk.1508

Tk.914

Tk.1509Tk.1516Tk.521

Tk.83

Tk.76

Tk.78

Tk.84

Tk.82

Tk.59

Tk.61

Tk.60

Tk.92

Tk.91

Tk.90

Tk.89

Tk.88

N. 87

85

Tk.86

Tank

Pump

House

ESS No.39

Control

Room

Flsmidtm

Weigh Bridge

Gt hrsg-6

W.t. N

o.8

W. Tank.9

Weigh Bridge

Weigh Bridge

Second Fire

Station

New TTL Truck Loading

Office

Old

TTL

Office

Weigh Bridge

105

104

106

107

No. 405

No.406 No.402

No.751

No. 755

Tank.752

Gen NAP

Tank No.753

Gen NAP

Tk.401

PFRCB

Tk.403

FGH

Tk.404

FGH

C

etra

l sto

re

W-T

N0-10

LPG PH.

T

on

w

eig

hb

rid

ge

B.H

.E

.L

E

le

ct w

ork shop

ESS

No.12

Mechanical

Workshop

Dust Bin

ES

S N

o.3

5

No.4

No.1

TPS Cooling

Tower

T.NO-1

T NO-2

No.2

No.3

No.304

No.303

No.302

No.301

ES

S N

o.1

3

New LPG Office

ESS No.20

W-T

Road No.23

Road No.22

AU - V

Unit

Ne

w R

oa

d N

o. 1

3

Road N

o.3

RoadNo. 02

Road No. 12

Road No. 04

Road

No. 05

Road No.2

Road No. 07

ISOM

Road

DHDS

Unit

NSU/NHT(2112)(48X116m)

I

XXV

IV

XXX

X

III

XXVI

II

XXVII

XXVIII

XXIII

XIX

XX

VI

V

IXVIII

XVI

XVII

XI

XIV

VII

XXIV

XXI

XVIII

XV

XXIX

XXXI

XXXVII

XXXVI

XXXII

XXXIII

XXXVIII

XXXXIV

XXXXII

XXXXI

XXXV

XXXX

New Flare Stack For GHP

Oily

Sludge

Lagoon

Sp

en

t C

au

stic

Tre

atm

en

t P

la

nt

W.O.T.T.L.

PH.

New DM Plant

(3 Streams)

D.M.W. Tanks

GTG (2117)

Unit

Switch Gear Bldg.

109

1100-01-TK-2

1100-01-TK-1

108

K.A.P.L.

S.M.P.L.

CRUDE

H.S.D.

L.D.O.

SKOKERO

NAPHTHA

CRUDE OIL

CRUDE OIL

Road N

o. 05

CRMB

PMP PLAT

R e l i a n c e A r e a

R e l i a n c e A r e a

R

e

l

i

a

n

c

e

A

r

e

a

R

e

l

i

a

n

c

e

A

r

e

a

R e

l i a

n

c e

A

r e

a

Y 265.43

X 398.45

X 990.781

LPG Mounded

Bullets

LPG Mounded

Bullets

LPG Mounded

Bullets

CO

KE

Y

AR

D

PIL

E (H

IG

H S

UL

PH

UR

)

Y 1920

Bharat Petroieum

Corporation Limiled

Transpoter

Repesentative

Setting

Room

Administrative Office

Amenity Bulding

Car

Parking

Store

Room

H.T.&

L.T.

Panel

Room

Ta

nk L

orry F

illin

g S

he

d

T.L.F. Pump

House

Tank 1

Tank 2

Tank 3

Tank 4

Tank 5

Tank 6

Tank 7

Tank 8

TT Crewrest

Room

Well

N

.

R

G

a

t

e

Guard

Post

Com

pound W

all

Pipe Corridor

Pump

House

Bridge

Gate No. 10

Truck Parking

Weigh Bridge

DHDT

TRUE NORTH

PLANT NORTH

N

N

NE

NW

5411

22

10

6

E

SE

WIND ROSE

W

24WS

S

GUJARAT REFINERY

NOTES :-

3-1641-0500 REV.2 A0-1189 x 841

REFERENCE DRAWING TITLEREF. DWG. NO.

APPDCHKDREVISIONSDATE

SCALE REV.DWG. NO.DEPT.DIVN.UNITJOB NO.

BY

1:5000

OVERALL PLOT PLAN

INDIAN OIL CORPORATION LTD.

BS-VI PROJECT

999 81 41 00001A885

NEW FACILITIES FOR BS-VI

EXISTING FACILITIES UNDER

CR

CT

F

CPU

C

1. ALL DIMENSIONS, COORDINATES AND LEVELS ARE IN

METERS UNLESS OTHERWISE SPECIFIED.

2.

3. LEVELS SHOWN ARE IN GTS MSL REF.

4. THE NEW SRR FOR THE PROPOSED BS VI PROJECT

SHALL BE INTEGRATED WITH THE EXISTING CONTROL

ROOM.

Cable Trench

Fencing

Tank

Green Area

Pond

Railway Line

Pipe Line

Pipe Line Corridor

Flood Light Post

Lamp post

Elect. Pole(with line)

Internal Wall

Wall

Borewell

Drain

Unit

Road

Boundary Wall

Building / Shed

Culvert

Unit

REVAMP FOR BS VI

ODC MOVEMENT ROAD

C

o

m

p

o

u

n

d

W

a

l

l

X 398.45

S/S

CPU

FGRS

FLARE

PRODUCT MOVEMENTGATE

HGUF

SS

AIR COMP.

CONS

T. W

/HLA

YDOW

N AR

EALA

YDOW

N AR

EABS

VI

BS V

I

CONSTRUCTIONAREA

OPEN STORAGEYARD (80X60)

FC-HCU (FUTURE J18)

BATCHINGPLANT 40X40

FCC GASOLINE FEED TANKPROPOSED(5000 M3)(BY DISMANTLING EXISTING TANKS)

F

ADDITIONAL 30,000 SQM FABRICATION AREA REQUIRED FOR FABRICATION:- IOCLTO IDENTIFY

feasibility report -...

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