1. 1
INDUSTRIAL ORIENTATION REPORT 2016
Prepared by
Daxit Akbari
3rd Year Petroleum Engineering
14BPE004
School of Petroleum Technology
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ACKNOWLEDGEMENT
First and foremost, I sincerely thank School of Petroleum Technology, Pandit Deendayal
Petroleum University, Training and Placement team which worked hard to organise the
Industrial orientation- 2016 and provide an invaluable and incredible opportunity to learn.
I find short of words in expressing my gratitude to all the speakers from the prominent industries
that provided the exposure to understand the petroleum value chain and gave a glimpse of ideas
that would pave my path to the future.
I want to appreciate all the industries (Reliance Jamnagar, Shell Hazira, Gujarat Gas
Gandhinagar, and Reliance Hazira) to provide an opportunity to look and scrutinize the practical
ideas very closely.
I am also grateful to the respective faculties Mr G.S. Negi, Mr Manan Shah and Mr Maunish
Shah for being an excellent mentor during the visits. I am also thankful to SPT Director and
PDPU administration for arranging such an organized Industrial orientation, where we got to
look into industries and organized series of technical and non-technical lectures which somehow
upgraded our practical thinking and concepts.
I would also like to thank Mr Vineet Bagaria sir as well as Training and Placement Cell, PDPU
for organizing such well scheduled and useful programme and arranging excellent transportation
facilities.
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INDEX
Sr. No Subject Page no.
1 Acknowledgement 2
2 Abstract 4
3 Learning From the Industrial Orientation 5
4 Reliance Petrochemical Complex Jamnagar 7
5 Shell LNG Terminal Hazira 19
6 Gujarat Gas Ltd. Gandhinagar 25
7 Reliance Hazira Manufacturing Division 33
8 References 39
4. 4
Abstract
The students of School of Petroleum Technology (SPT), PDPU are required to undergo
industrial visits at related industries of their curriculum.
This report refers to the various industrial visits conducted by SPT.
Industrial visits represent important activities in any engineering undergraduate
programme that contribute to the achievement of various essential learning outcome and
programme objectives.
This report provides an overview of Industrial visit as well as overview of individual
industry.
This report gives insight the work carried out by the students as well as Production
Process flow diagrams.
This report also carries the technical aspects and working of various units such as
CDU, DRS, PTA Plant, Odourant system, Heat Exchanger, SPM etc.
At last, this report gives an outcome of overall industrial programme and practical aspects
and key learning.
This report describes the procedures and the lessons learnt from such programme and
responsibilities to assist and provide good guidelines to ensure all students achieve the
objectives of industrial orientation in future also.
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Learning From the Industrial Orientation
Industrial Orientation was an opportunity to broaden our understanding of the industry
and experiencing the practical application of theories learnt in the class.
Following are the key learning from this Industrial Orientation Program
Different instrument of petroleum industry which are used now a day to maintain &
monitor the temperature, pressure, flow rate.
Different types of crude oil refining process, cracking techniques, process control by
online monitoring.
Backward integration of Reliance by Dhirubhai Ambani to built India's largest private
sector company in Petroleum Industry.
Storage and Re-gasification of LNG. Working principle of heat exchanger
Safety is our first priority in Hydrocarbon Industry - Shell LNG Hazira Terminal
Technical importance of Jetty and Single Point Mooring (SPM) system.
Various petroleum products loading and unloading process.
City Gas distribution (CGD), CNG compressor working, District Regulating Station
(DRS), maintaining pressure, flow rate, odorisation, gas metering etc.
Inside PTA plant visit was one of the great experiences for us and great opportunity to
feel the industrial environment.
Presentation by reliance hazira employee suggested us to decide our long term goal not
just short term.
Carrier building lecture was become a true path finding experience for me.
This Industrial Visit has given me an overview of the industry to build my career in a
proper direction and it will help me to choose right industry in future.
As a student coordinator, I learn how to deal with people of different mind sets and
arrange all facilities for students.
Industry needs people who are updated with time through learning new technologies in
respective field.
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We need to develop our own laws to understand every technical process and create a
burning desire to learn something new and build new technologies that provide energy to
the people easily and efficiently.
Group Photo
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Reliance Petrochemical Complex
Jamnagar
Overview
Reliance Industries Limited (RIL), the flagship company, is a Fortune Global 500
company and is the largest private sector company in India.
The Jamnagar manufacturing division is the world's largest refining hub with
crude processing capacity of 1.24 million Barrels Per Stream Day (BPSD).
The Jamnagar complex is a fully integrated manufacturing facility, with a petroleum
refinery complex, an aromatics/petrochemical complex, a power generation complex
and a port and terminal complex that provides access to a pipeline network.
Location
Situated on the northwest coast of India, the integrated refinery-cum petrochemicals
complex of Reliance is located at village Motikhavdi, Lalpur Taluka, Jamnagar
District, in the state of Gujarat.
The complex is in proximity to the Gulf of Kutch, a sheltered bay close to the
Middle-East crude oil sources.
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Total area
The entire Jamnagar complex, consisting of manufacturing and allied facilities such
as utilities and off-sites, port facilities and a township for the employees, sprawls over
more than 7,500 acres.
Total investment
The entire Jamnagar complex entailed a total investment of about 25,000 crore Rs
(about US$ 6 billion).
Refining processes
The refinery complex at Jamnagar has more than 50 process units, which together
process the basic feedstock, crude oil to obtain various finished products deploying
the following major refining processes:
1) Crude oil distillation (Atmospheric as well as vacuum distillation)
2) Catalytic cracking (Fluidised Catalytic Cracker)
3) Catalytic reforming
4) Delayed Coking
Capacity
i. J1-DTA ( Domestic Tariff Area ) : 33 mmtpa
ii. J2-SEZ ( Special Economic Zone ): 27 mmtpa
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Unique Features
Reliance Jamnagar refinery has state of art technology to process more than 148
types of crude including high sulphur content crudes also.
Reliance Jamnagar refinery has refining margin of approximately 10 $/bbl which is
highest among all refineries in INDIA.
Reliance Jamnagar refinery is now one of the most complex refineries in the world
with Nelson complexity index of 14.
Jamnagar Complex has become the petroleum hub of the world and represents about
2% of global crude processing capacity.
Township
The complex includes a self-contained township, appropriately named as Reliance
Greens, for over 2,500 Reliance employees and their families.
Sprawling over 415 acres of land, the township has been designed to provide the best
possible residential, educational and recreational facilities to the employees.
The township includes fully furnished housing for the employees, as well as a
medical centre, school, playgrounds, temple, community centres, health centres,
banks, mall/supermarket, gas station, parks, swimming pool, golf course and tennis
courts etc.
Automated Control Panel of SEZ Refinery
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From control panel screens panel operators analyze specifications and control
continuous operation of petroleum refining and processing units.
They regulate temperature, pressure, rate of flow, and tank level in petroleum refining
unit, according to process schedules.
Online control of all refinery processes from single location makes it easy to operate
and taking quick actions during any type of emergency.
Panel operators can change the production capacity of every plant as per availability
of feed stokes and customer demand.
Panel operators can also adjust the quality of product as per customer requirements
Refining Process
Main Components of Distillation Columns
A vertical shell where separation of liquid components is done.
Column internals e.g. trays/plates and/or packing which are used to enhance
component separations.
A re-boiler to provide the necessary vaporization for the distillation process.
A condenser to cool and condense the vapour leaving the top of the column.
A reflux drums to hold the condensed vapour from the top of the column so that
liquid (reflux) can be recycled back to the column.
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Distillation Column
1. Atmospheric Distillation
Crude Oil contacted with 3- 10% water @ 230-260 °F to remove salts and sediment (
fine sand, clay, soil) to minimize corrosion and fouling.
The feedstock then flows to a direct‐fired crude charge heater then into the vertical
distillation column just above the bottom, at pressures slightly above atmospheric and
at temperatures ranging from 340‐370°C (above these temperatures undesirable
thermal cracking may occur).
Molecules are separated by boiling ranges, but not chemically altered.
As the hot vapour rises in the tower, its temperature is reduced. Heavy fuel oil or
asphalt residue is taken from the bottom.
At successively higher points on the tower, the various major products including
lubricating oil, heating oil, kerosene, gasoline, and uncondensed gases (which
condense at lower temperatures) are drawn off.
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2. Vacuum Distillation
To further distill the residue crude from the atmospheric tower without thermal
cracking, reduced pressure is required.
The principles of vacuum distillation resemble those of fractional distillation except
that larger diameter columns are used to maintain reduced pressures.
Vacuum Distillation Column
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3. Fluid Catalytic Cracking
FCC unit Convert heavy hydrocarbons into lighter products – primarily gasoline
FCC is the largest gasoline producer in refinery
Cracking of heavy hydrocarbons forms coke on catalyst, burned off in regenerator
Most of the heat required in the reaction is produced from coke burn on catalyst
(Silica-alumina)
Catalyst degrades over time due to metals, sulphur. Fresh catalyst added to maintain
activity
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5. Refined Petroleum Products and Their Uses
Reliance Jamnagar refinery processes a wide variety of crude oils and produces a
range of petroleum products for exports as well as supply in the Indian market.
Products Applications
Liquefied Petroleum Gas (LPG) Domestic and industrial fuel
Propylene Feedstock for polypropylene
Naphtha Feedstock for petrochemicals
Gasoline Transport fuel
Jet /Aviation Turbine Fuel Aviation fuel
Superior Kerosene Oil Domestic fuel
High-Speed Diesel Transport fuel
Sulphur Feedstock for fertilizers and pharmaceuticals
Petroleum Coke Fuel for power plants and cement plants
Reliance Jamnagar Marine Terminal
Reliance Jamnagar Marine Terminal is situated in the Gulf of Kutch, State of Gujarat,
India, about 35 km west of the town of Jamnagar. The Marine Terminal was
inaugurated in 1999.
It is used for unloading crude oil from Gulf countries and loading of different
petroleum products into the ships. It is also used for receiving huge size refinery
equipment e.g. distillation towers from ships.
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SPM-Single Point Mooring
The marine facility has 3 SPM’s - Single Point Mooring (one is only for
petrol, second is only for diesel and third is for other products) for crude oil
import. SPM system is built for large size ships which can't go very near to
sea shore.
Top part of SPM is rotating with the rhythm of ship and bottom part is non-
rotational.
The top and bottom sections are linked by a roller bearing, referred to as the
"main bearing".
Bottom part is held in place by multiple radiating anchor chains.
The marine facility also has 5 Tanker Berths A, B, C, D and E for exporting products
and a seawater intake facility for cooling water requirements.
The marine facility also includes a Ro-Ro facility and unloading platforms for
handling Project construction cargo.
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The product pipelines from the existing Jamnagar refinery were routed from Marine
Tank Farm (MTF) to Land Fall Point (LFP) on onshore RCC sleepers and steel
frames. These then travel on pile supported RCC pile caps and steel frames along
1400 m long shore link between LFP and Zero Point.
Green Belt
Reliance Jamnagar has developed a unique greenbelt in and around its refinery
complex.
It covers an area of slightly over 1600 acres, where more than 200 species of plants
are raised with over 3.2 million trees.
The impact of this massive greening has resulted in lowering of temperature by
around 20 °C and increase in annual rainfall from an earlier average of 400 mm to
over 600 mm as seen from the last 3 years’ records.
As a part of greening activities, Reliance, Jamnagar has developed Asia’s largest
mango orchard encompassing 447 acres. It is named Dhirubhai Ambani Lakhi Baug.
Trees in mango and other fruit or chards are irrigated with desalinated water or fresh
water.
Wind velocity at Jamnagar at times goes up to 70 Kms /hour. In order to protect
flowering and fruiting of such trees, plantation of a wind-breaking-cum filtering Saru
trees is taken up surrounding fruits orchards.
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Shell LNG Terminal Hazira
Overview
Shell Hazira Port, a unit of Royal Dutch Shell, operates the terminal and owns 74%
interest in the facility. Total Gaz Electricité France holds the remaining 26%.
The Hazira Terminal includes a liquefied natural gas (LNG) storage and re-
gasification terminal within a fully functional port.
Location
Shell LNG Terminal is situated in the State of Gujarat on the West Coast of India,
about 25 km from Surat city and about 120 nautical miles north of Mumbai.
The area is located near key markets for gas and connected to the gas grid in Gujarat.
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Total area
The entire LNG terminal spread over an area of 46.7 hectares, the terminal has a jetty
where LNG cargo is unloaded through to the cryogenic tanks
Total investment
The Rs 3,000 crore Hazira LNG Terminal and Port facilities, in Surat district of
Gujarat, is regarded as a key foreign direct investment (FDI) project and represents
one of the largest international investments in India in the energy sector.
Capacity
i. First LNG Storage Tank: 1,60,000 𝑚3
ii. Second LNG Storage Tank: 1,60,000 𝑚3
Unique Features
The Hazira LNG terminal was the first to introduce Spot LNG supplies into India.
Hazira has received LNG supplies from all the major LNG producing nations and its
Terminal is able to accept LNG ships up to Q Flex sizes.
The Hazira LNG Terminal is now interconnected with the Hazira-Vijaypur-
Jagdishpur line (HVJ), Dahej-Uran pipeline (DUPL), Gurjarat State Petronet Limited
(GSPL) and East West pipelines at Mora, enabling Shell to supply gas to North,
West, Central and even South India.
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LNG -Liquefied Natural Gas
When natural gas is cooled to a temperature of approximately -160 °C at atmospheric
pressure, it condenses to a liquid called liquefied natural gas (LNG).
One volume of this liquid takes up about 1/600th the volume of natural gas.
LNG is odorless, colorless, non-corrosive, and non-toxic. When vaporized, it burns in
concentrations of 5% to 15% on being mixed with air.
LNG or its vapour is not explosive in an unconfined space.
Re-Gasification Process
The re-gasification process at the terminal involves heating of the super cool LNG (-
160℃) to transform it back into gas. Heating is carried out using two types of heat
exchangers.
The converted gas is sent through a 17 km pipeline to the Mora Gas Hub. Owned and
operated by Gujarat State Petronet, the Mora Gas Hub delivers gas to various
industries such as steel mills.
Technical Features of Shell LNG Hazira Terminal
1. LNG Jetty
The LNG jetty has two liquid unloading arms both of which are cryogenic and are
designed to unload LNG at -160℃.
Unloading of LNG can be done at a maximum rate of 11,000 𝑚3
/hour.
The jetty has state of art Emergency Shutdown System and safety equipments to
avoid & control spills and leaks of LNG.
The LNG unloaded is carried in cold condition by a 1.6 Km pipeline to the LNG
tanks.
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2. LNG Storage Tanks
The terminal has two LNG tanks with a capacity of 1,60,000 𝑚3
each.
These tanks have pre-stressed concrete outer and 9% Nickel steel inner tank to
hold the LNG at -160 ℃
LNG is stored in the tanks at atmospheric pressure.
Cold insulation is provided between the outer and inner tanks to minimise heat
ingress to the tank. This would ensure that LNG can be stored in the tanks at low
temperature with minimum vaporisation of LNG.
The LNG tanks are large with inner tank diameter of 79 m.
The tanks are provided with protection against high pressure to avoid any damage
and with robust controls to keep the pressure within limits.
LNG cryogenic pumps are installed inside the tanks, which pump out LNG from
the tanks at intermediate pressure.
The LNG pressure is finally boosted to 100 bars with the help of high speciality
multi stage cryogenic pumps before being sent to the re-gasification section.
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3. LNG Vaporizers
LNG is regasified in Open Rack Vaporisers, using sea water as the heating
medium.
Sea water is first filtered to remove solids before sending it into ORV. Sea water
temperature goes down to 3 ℃ after giving the heat to LNG.
Terminal has three Open Rack Vaporisers which are used to vaporise LNG.
Vaporisers’ design ensures proper distribution of seawater.
These vaporisers are designed to handle LNG at -160 ℃ and have been provided
with instrumented protections to avoid any damage.
The terminal also has a Submerged Consumption Vaporiser which uses fuel gas
as the source of heat. In these vaporisers, heat generated by burning fuel gas is
used to warm the water which in turn vaporizes LNG.
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4. Pipeline Connectivity
A 12.5 Km, 28 inch pipeline transports high pressure gas to the Hazira Mora
Metering Station where the custody transfer takes place.
The Metering station is equipped with Custody Transfer quality Ultrasonic type
gas metering facility and pressure control facility to supply gas to various
customers at required pressures.
A fibre optic cable laid along the pipeline connects the pipeline controls to the
terminal control room which enables the operation of the Metering Station.
The pipeline and the metering station are equipped with various protection
systems to avoid & minimise any gas leak.
The Hazira Mora Metering Station is now interconnected to GAIL, GSPL and
RGTIL pipelines at Mora.
Uses
The Hazira LNG terminal operates and supplies LNG to a large number of customers
in different industrial segments ranging from power and fertilizer to ceramic, steel,
small and medium industries.
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Gujarat Gas Ltd.
Overview
Gujarat Gas Ltd. is a Gas distribution company which has its own distribution system
in which CNG & PNG sold to various segments by interconnecting gas pipeline &
related equipments.
Gujarat Gas Limited has emerged as India's largest city gas distribution player with
presence spread across 19 Districts in the State of Gujarat and Union Territory of
Dadra Nagar Haveli and Thane GA which includes Palghar district of Maharashtra.
Location
Gujarat gas CNG mother station is located between G-2 & G-3 Circle, Sector 5,
Gandhinagar district, Gujarat state.
GSPL SV Station & CGS is located near ambapur village, taluka and district
Gandhinagar, Gujarat state.
Capacity
Mother Station CNG Compressor Capacity: 1200 SCMH
Unique Features
Gujarat Gas is India's Largest City Gas Distribution Company.
Gujarat Gas has built network of over 16,000 km-long gas pipeline and 230 CNG
stations constituting 22% of all CNG stations in the country.
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Gujarat Gas provides 5.5 MMSCMD of Natural Gas to 34% of all domestic
customers (10, 80,000), 50% of all Commercial customers and 46% of all Industrial
customers in India.
City Gas Distribution Business:
A City gas distribution means a distribution system in which CNG & PNG sold to
various segments by interconnecting gas pipeline & related equipments.
Currently the CGD segment constitutes 12 percent of the total gas consumption in
India. It is worth noting that this has been achieved in the past five years itself. It is
expected to reach a share of 20 percent by FY 20.
Increasing demand from commercial and small industrial customers within the city
limits, in addition to the automotive and residential demand, are the key drivers of
growth in this segment.
CGD demand of natural gas from 2012-13 to 2029-10 of India.
MMSCMD 2012-13 2016-17 2021-22 2026-27 2029-30
CGD 15.30 22.32 46.25 67.96 85.61
City Gas Distribution Network
A typical CGD Network shall comprise of one or more or all of the following:
1. City Gas Station (CGS)
2. Pipeline Network – Steel Pipeline, Polyethylene Pipelines, GI/Cu Pipes
3. Regulating Stations – District Regulating Stations (DRS), Service Regulators,
4. Metering Stations
5. CNG Stations
27. 27
City Gas Station (CGS)
It is established at a tap-off point of high pressure transmission pipeline; from where we
get gas inside the city via pipelines.
Custody Transfer from Transmission Company to Distribution Company
The gas delivered at this point is at higher pressure i.e. greater than 50 bar. Once gas
enters to CGS unit its pressure is reduced to in between 24-30 bar.
Odorization Unit
Natural gas is colorless and odourless in order to detect gas leakage ethyl mercaptan is
added as an odourant for east detection of gas leakage. Ethyl mercaptan has a very bad
smell.
An Odorization unit is installed for addition of ethyl Mercaptan in the gas stream.
As per the PNGRB guidelines odourless gas should not be provided to customer for
safety purpose.
The dozing unit of the ethyl Mercaptan is in between 10 - 20 mg/𝑚3 as per requirement.
This unit consists of mainly one cylinder of capacity of 500 litres, pneumatic panel, level
indicator and a filter.
Ethyl Mercaptan boils at 35℃. In order to stable its liquid state, high pressure gas blanket
is provided above it in storage tank so 20 volume % of the storage tank is filled by high
pressure gas.
During pumping, doping rate is calculated in liquid state.
Odorization unit is directly connected to the main line.
Vericonne Company is service provider of Ambapur odorisation unit.
A typical odorisation unit
28. 28
District Regulating Station- DRS
DRS are the device used to reduce the pressure from 24 bars to 4 bars.
It is the interface between the steel grid network and medium pressure network. It is
located at various demand centres for domestic /commercial users
The flow capacity of DRS is in range of 5000-10000 SCMH.
DRS regulate gas pressure from 20-25 to 4 bar.
The inlet line of DRS is steel pipeline and outlet is polyethylene pipeline.
DRS has two streams, one is active stream and other is stand by stream.
Components of DRS
1. Gas Filters
2. Pressure reduction:
i. Active regulator
ii. Monitor regulator
iii. Slam Shut off Valve for over pressure protection
iv. Creep Relief Valve.
3. Pressure Gauges
4. Heaters (if required)
5. Pilot regulators
6. NRV: Non- Return Valve
7. Inlet/outlet isolation valves
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Filter PRV
Monitor Regulator & Active Regulator
SSV PRV
Equipment Set Pressure (bar)
PSV 42.0
SSV 5.2
CRV 5.0
Monitor Regulator 4.5
Active Regulator 4.0
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CNG
CNG Refuelling Station is a facility set-up for supplying CNG mainly as a fuel to
vehicles. The system receives odorized gas at certain pressure (19 Bar), through
transmission line and supplies the same to the customers/vehicles after filtration,
compression (upto 250 Bar) and check metering.
Types of CNG Refuelling Stations
1. Mother Station: A CNG station provided with whole set up (compressors, dispensers,
cascade etc.) along with Light Commercial Vehicles (LCV) filling point is known as a
mother a CNG station.
2. Online Station: This CNG station has same set up as a mother station but LCV connection
is not provided for filling.
3. Daughter Booster Station: Daughter station provided with the compressor (known as
boosters) to compress the gas which comes from the mother station are known as daughter
booster station.
4. Daughter Station: Daughter stations are established in those areas where laying a pipeline
is not possible. In that case gas is delivered from mother station to daughter station; via
mobile cascade van. The gas from mother station is filled in mobile cascade by a LCV filling
point.
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Types of CNG Station
CNG Compressor
Steel line of 2 inches dia. coming to compressor as a suction line (25 bars). Suction line is
provided with isolation valve followed by a strainer for removing of foreign particles.
The first stage is double acting stage; here compression is affected from both the ends of
the cylinder of the compressor. Then gas is sent to the intercooler for the cooling of the
gas.
Now gas from intercooler enters to second stage for the compression. Second stage is
single acting means one suction and one discharge. After compression it goes to
intercooler for air cooling of the compressed gas.
Finally it reaches to third stage (single acting) for final compression from intercooler for
the desired final pressure of gas.
At every stage, the gas pressure and temperature is:
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Safety Units in Compressor
Flame detectors and Gas detectors
CO2 flooding system
Safety Relief Valve (SRV)
Cascades
A bank of cylinders used for buffer stock of compressed natural gas is known as cascade.
Stationary cascade is used to store the gas when vehicle is not there at the dispenser then
the gas from compressor flows into a cascade.
1) Stationary Cascade: These are fixed cascades established on CNG station for the
storage of CNG. It has a direct inlet from compressor and outlet to line connected
to dispenser.
2) Mobile Cascade: Cascade is mounted over an LCV and it carries CNG from
Mother Station to Daughter station or Daughter booster station as per the
requirement.
Cylinders in a cascade are divided accordingly as:
- High Pressure Cylinders (HP) - 5 cylinders
- Medium Pressure Cylinders (MP) - 15 cylinders
- Low Pressure Cylinders (LP) - 20 cylinders
-
Stationary Cascade
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Reliance Hazira Manufacturing Division
Overview
Hazira Manufacturing Division (HMD) of Reliance Industries Limited (RIL) is a
multi-product, fully integrated complex, manufacturing a wide range of
petrochemicals, polymers, polyesters and polyester intermediates. The complex
comprises of a Naphtha cracker feeding downstream petrochemical, fibre
intermediates and polyester plants.
The Hazira petrochemical plant was commissioned in 1991–92.
Major operations at Hazira involve production of Ethylene and Propylene by Naphtha
cracking, production of fibre intermediates (Purified Terephalic Acid and Mono-
Ethylene Glycol), manufacturing of polyesters (Partially Oriented Yarn, Polyester
Staple Fibre Poly-Ethylene Terephthalate) and polymers (Polypropylene,
Polyethylene and Polyvinyl Chloride).
The Hazira manufacturing division has two elastomer plants producing PBR and SBR
each.
Location
Hazira Manufacturing Division (HMD) of Reliance Industries Limited (RIL) is
located at village Mora, near Hazira in Choryasi Taluka of Surat District in the State
of Gujarat.
Area
Hazira Manufacturing Division spread across 1000 acres.
34. 34
Capacity
RIL operates a world scale manufacturing division at Hazira (RIL-Hazira), producing
nearly 7 million MT of products annually.
Investment
Over US$ 3 billion has been invested at RIL, Hazira.
Unique Features
RIL-Hazira secured 1st rank with lowest Steam Leakage Ratio across RIL
Petrochemicals sites.
PBR & SBR
Reliance high quality PBR and SBR is sold in bales, each weighing 35 kilograms and
measuring 28 x 14 x 8 inches. The finishing lines at Hazira manufacturing divisions
are fully automated.
All products from Relflex Elastomers is wrapped with an inner layer of perforated
Low Density Polyethylene (LDPE) and further packaged in paper bags.
As part of quality assurance, all materials are pre-scanned for unwanted foreign
particles. It is only after passing each bale through a series of quality checks that the
material is dispatched to our warehouses.
Date and location of manufacture, along with other standard specifications are printed
on each package.
Standard 35 kg bale
35. 35
PTA Plant Visit
PTA, which is pure white powder obtained from Para Xylene.
36. 36
Process Flowchart
Process Description
The PTA process has two stages:
Oxidation – Forming Crude Terephthalic Acid (“CTA”) from Paraxylene (“PX”)
Purification – Purifying Crude Terephthalic Acid (“CTA”) into Purified Terephthalic
Acid (“PTA”).
37. 37
1. Process feedstock
The process feedstock is p-xylene dissolved in acetic acid with the inclusion of hydrogen
bromide, manganese and cobalt salts as catalysts.
2. Oxidation
The liquid feed enters the oxidation vessel where step-wise oxidation of p-xylene’s
methyl groups produces crude terephthalic acid (CTA):
The CTA is largely insoluble, and consequently the reactors contain significant amounts
of solid product crystals. The main impurity of the CTA relative to PTA is determined by
the 4-carboxy benzaldehyde (4-CBA) content.
3. Crystallization, filtration and drying
Flash cooling further crystallizes product from the slurry. The solid CTA is then
separated and dried, before being re-slurried in water in preparation for purification.
4. Purification (hydrogenation)
CTA purification proceeds by hydrogenating the 4-CBA impurity back to para-toluic
acid, using a heterogeneous palladium-on- carbon catalyst.
The CTA-water slurry is pre-heated to aid dissolution, before progressing to the
hydrogenation
reactor, where the addition of hydrogen initiates the following reaction
38. 38
The p-toluic acid is much more soluble in water than terephthalic acid, allowing the PTA to
crystallize from solution by flash cooling while the p-toluic acid remains dissolved.
Filtration, washing and drying follow to give solid PTA
Final Product
5. Application
PTA is predominantly used as a raw material in manufacture of Polyester Staple Fibres, Polyester
Filament Yarns and Polyethylene Terephthalate in conjunction with Mono Ethylene Glycol (MEG).
Polyester Fibres/Yarns find application in the production of textiles and films. PTA also finds use in
small quantities in the manufacture of paints, etc.
