AROMATICS & DOWN STREAM PROCESS

T.K.BASAK GM(PC) IOCL-RHQ

AROMATIC COMPLEX
CH3

PX - ParaXylene
CH3 COOH

PTA - Purified Terephthalic Acid

( 1-4 Benzene Dicarboxylic Acid)

COOH

PX COMPLEX

PX Complex - Block Flow Diagram

HYDROGEN LPG RAF. NAPHTHA BENZENE

BZ & TOL. HEART CUT NAPHTHA TOLUENE

NHTU

SULFOLANE

BTF

TATORAY

BENZENE & XYLENE

CCRU

C7- STREAMS C9 AROM. MIXED S XYLENE

REFORMATE

XFU

PAREX

O &M S XYLENE

ISOMAR

MIXED ES XYLEN

PX HY AROMATICS

Units in PX
Whole complex divided into two blocks. PX-1
Naptha HydroTreater, Platformer/CCR Unit PSA, Recovery plus Unit Benzen Toluene Fractionation (BTF) Shell Sulfolane Unit (SSU),

PX-2 Xylene Fractionation Unit Parex Unit Isomar Unit Tatoray Unit

PX-COMPLEX
UNIT
NAPHTHA SPLITTER : - AT MATHURA - AT PANIPAT NAPHTHA HYDROTREATER/ CCR PLATFORMER XYLENE FRACTIONATION UNIT

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

Production of high purity benzene and toluene (to BENZENE/TOLUENE FRACTIONATION AND be used as secondary feedstock for increasing PX SULFOLANE EXTRACTION UNITS production) PAREX ISOMER UNIT For recovery of high purity Para-xylene from mixture of C8 aromatic isomers For re-establishing equilibrium mixture of isomers in the PAREX unit raffinate to improve the yield of Para-xylene For disproportionation and trans-alkylation of Toluene alongwith C9 aromatics for maximizing Para-xylene

TATORAY UNIT

PX BLOCK UNIT CAPACITY

UNIT NAPHTHA HYDROTREATING CCR SHELL SULFOLANE EXTRACTION BTF PAREX XFU TATORAY ISOMER CAPACITY - KTA 500 500 152.2 379.8 2025.4 481.7 360.2 1656.5

NAPHTHA HYDROTREATING UNIT

FLOW DIAGRAM
H e a te r N a p h th a F e e d F e e dS u rg e D ru m S e p a ra to r R e a cto r r S trip p e L ig h tE n d s toF u e l

S o u r W a te r W a te r H yd ro tre a te dN a p h th a toC C RP la tfo rm in gU n it M a ke -u p H yd ro g e n

Stacked Reactor Catalyse Regenerator

CCR PLATFORMING UNIT FLOW DIAGRAM

Feed/ Effluent Exchanger Recontacting Drum

Net Gas Recontacting Section

Chloride Treater

Fresh Catalyst Fresh Feed from Naphtha Hydrotreater

Fired Heaters Net Hydrogen Product

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.

Reformate Product to Reformate Splitter Debutanizer Steam

Unstabilised LPG

SULPHOLANE UNIT
FLOW DIAGRAM
Raffinate Product to storage Anti Foam Recovery Column To Ejector

Extractor Feed Surge Drum

MEA Steam Reformate Splitter Overhead Raffinate Wash Column Solvent Regenerator Extract to Clay Treaters in BT Frac. Unit Steam

Stripper

Benzene from Tatoray Unit

Steam Steam

Intermittent

Water Stripper Make-up Solvent

BENZENE TOLUENE FRACTIONATION UNIT

Toluene Column Benzene Column

Benzene Product to Storage Clay Treaters Clay Treater Charge Tank

Benzene Drag

Toluene to Feed Surge Drum at Tatoray unit

16 ATA

Recovery Column Overheads from Sulfolane unit

HP Steam

Finishing Column Overheads from Parex unit

Stripper Bottoms from Tatoray Unit

C8+ aromatics to Clay Treater Feed Heater at X ylene Fractionation Unit

PAREX UNIT
FLOW DIAGRAM
1 13 12 Rotary V alve 24 E x trac t Colum n E x trac t Finis hing Colum n Toluene to Tatoray Unit Fix ed from Xy lene S plitter Overhead (via Is om ar Unit)

Xy lene S plitter Overhead Line Flus h

S team

W ater Injec tion

p-Xy lene P roduc t to S torage

Secondary Flush

Raffinate S urge Drum

Raffinate to Is om ar Unit Des orbent S urge Drum Xy lene S plitter Overhead S team Des orbent M ak e up Desorbent P um p Out toTank age Heavies to Fuel Oil (Interm ittent)

Parex Adsorbent Section

FRC Head Flush AR
1

RV

Head Flush

D Ho

Hi F

13

E X R
12

PRC

PRC

24

Head Flush

Head Flush FR Pumparound

Pusharound

ISOMAR UNIT
FLOW DIAGRAM
Parex Reffinate from Raff. Surge Drum Light Ends to Fuel gas System Purge gas Heater Reactor Separator Xylene Splitter Overhead Deheptanizer Ovhd Liquid to Platforming unit Debutanizer

Clay Treater

Make-up Hydrogen from Tatoray or Platforming

Dehepanizer Bottoms to Xylene Splitter

TATORAY UNIT FLOW DIAGRAM

Feed Surge Drum Heater Separator Reactor Toluene from Toluene Column C9 Aromatics from A9 Column Toluene from Parex unit Purge Gas to Isomar Unit Stripper

Liquid end to fuel gas system

Ovhd Liquid to Platforming Unit Debutaniser

Recycle Gas

Benzene Column Make-up Hydrogen from Platforming unit Benzene to Sulfolane Unit

to Clay Treaters in BT Fractionation Unit

Steam

PX Complex - Products
(In Tons Per Annum ) CASE BOMBAY HIGH N APHTHA FEED RATE 500,000 PRODUCTS Paraxylene 361600 Benzene 24100 Raffinate Naphtha 26100 Net H 2 Rich gas 28000 LPG 15000 Light Ends 31000 Heavies 14200 Tot al 500,000 BONN Y LIGHT NAPHTHA 500,000 364 200 32500 31000 35700 12600 14300 4700 500,000

PTA

PTA PROCESS
1ST STAGE- OXIDATION PROCESS
PARAXYLENE + OXYGEN = TA + H2O+HEAT
REACTION TAKES PLACE IN PRESENCE OF CATALYST & SOLVENT. HEAT LIBERATION = 3000 KCALS/KG OF PX
P-XYLENE 4-CARBOXY BENZALDEHYDE TA PARATOUALDEHYDE PARATOLUIC ACID

PTA Units Block Flow Diagram

OXIDATION REACTORS
CH3 COO H COO H COO H COOH COO H CHO

H2 DISSOLVER REACTOR PTA CRYSTALLISERS

CTA CRYSTALLISERS

CH3

PARAXYLENE + Acetic Acid

Compressed Air

ROTARY VACUUM FILTER

CTA DRYER

CENTRIFUGES

PTA DRYER

ST

E
PRODUCT HOPPERS

PA COMPRESSOR

PURIFIED TEREPHTHALIC ACID - PROCESS

PTA CAPACITY IN INDIA

TMTPA

RIL Patalganga RIL Hazira MCCPTA, Haldia IOCL Panipat Total

1155 730 600+800 553 3838

PTA SUPPLY-DEMAND SCENARIO

PTA DEMAND FORECAST BY NEXANT
YEAR 2009 2010 2015 2020 DEMAND TMTPA 3162 3386 3973 4645
EXISTING INSTALLED CAPACITY : 3838 TMTPA TILL 2015, INSTALLED CAPCITY IS JUST SUFFICIENT TO MEET MARKET DEMAND IN FUTURE, GAP EXISTS & CALLS FOR ADDITIONAL PTA CAPACITY.

POLYMERS

AROMATIC BASED POLYMERS - FEED STOCK

NAPHTA C5+AROMATICS

BENZENE PS

O-XYLENE Plasticizer, NYLON Paint additive

PSF/ PFY

P-XYLENE

PET

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 OH COOH 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 OH O C] O

COOH

PET PROCESS FLOW DIAGRAM

Reactor-1 Condensation Polymerization

Reactor-2 suspended solid polymerization*

Chipping Section

Final Crystallization

PET

* For improving intrinsic viscosity

PET PROPERTIES
Hard Stiff Strong Dimensionally stable material that absorbs very little water Good 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 resistance Very good heat and heat ageing resistance Very low creep, even at elevated temperatures

PET GRADES & APPLICATION

Grade

Process/ Intrinsic Technology Viscosity

(dL/g) Polycondensatio n/SSP 0.76-0.84

Applications

Bottle

Bottled water, Carbonated soft drinks, Edible oil, Country Liquor, Pharmaceuticals Cosmetics, Household jars Packaging, Metallic yarn, Audio video tapes, Power cables Fibres for a very wide range of textile & industrial uses (Dacron,Trevira,Terylene)

Film Fibre

Polycondensatio n/Extrusion Polycondensatio n/Extrusion/ Drawing Fibre

0.64-0.66 0.6-0.63

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 OH COOH Manufacture of PSF consists of 4 steps: 1) Polymerization: Using PTA/DMT and MEG on either batch or continuous polymerization forming final polymer 2) Melt spinning :Here molten polymer is forced through spinneret holes to form undrawn filaments, to which spin finish is applied and coiled in can OH O C] O

COOH

PSF STRUCTURE & SYNTHESIS (contd)

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 PROCESS FLOW DIAGRAM

Reactor Condensation Polymerization

Spinning Section

Draw Section

Cutting Section

Baling Section

PSF Bales

PSF PROPERTIES

Quality 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) 3.0 3.5 4.8 5.0 6.0 6.4 Application

LOW PILL MEDIUM HIGH

Generally used for knitting 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. used for spinning 100% polyester sewing threads & other industrial yarns

SUPER HIGH

7.0 plus

PSF TECHNOLOGY OVERVIEW Major Licensors:

Invista (erstwhile Dupont), USA EMS- INVENTA

Zimmer AG, Germany

Noyvalesina, Italy

VALUE ADDITION FROM PTA BY PRODUCTION OF PBT

Poly butylene Terephthalate Production(PBT)

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

Thank You