detailed feasibility study report for poly propylene unit of ...

DETAILED FEASIBILITY STUDY REPORT

FOR

POLY PROPYLENE UNIT

OF

NUMALIGARH REFINERYEXPANSION PROJECT

AT

NUMALIGARH REFINERY LTD, ASSAM

REPORT NO. B394-RP-79-41-0001 VOLUME 1 OF 1

OCTOBER 2021

This report is prepared for M/s NRL and it is for use by M/s

NRL or their assigned representatives/organizations only.

The matter contained in the report is confidential.

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Document No.

B394-RP-79-41-0001

Rev. No. B

Page 1 of 1

Copy right for DFR

Poly Propylene Unit of Numaligarh Refinery

Expansion Project (NREP)

NRL

COPYRIGHT

This document is copyright protected by EIL and is produced for the client M/s

NRL. 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:

Head of the Department (Process - 2)

5th Floor, Tower II

R&D Complex, Engineers India Limited

Sector-16, Gurgaon- 122001

India

Telephone: 0124-380-2901

EIL reserves the right to initiate appropriate legal action against any

unauthorized use of its Intellectual Property by any entity.

Template No. 5-0000-0001-T2 Rev. 2/ 28.11.2014 Copyright EIL – All rights reserved

Document No.

B394-RP-79-41-0001

Rev. No. B

Page 1 of 1

Table of Content for DFR Poly Propylene Unit of Numaligarh Refinery

Expansion Project (NREP) NRL

TABLE OF CONTENTS

SECTION CONTENTS

1. EXECUTIVE SUMMARY

2. INTRODUCTION

3. SCOPE

4. DESIGN BASIS

5. MARKET STUDY

6. PROJECT LOCATION

7.

7.1

7.2

7.3

7.4

7.5

7.6

7.7

PROJECT DESCRIPTION

PROJECT CONFIGURATION

PROCESS DESCRIPTION

MATERIAL BALANCE

UTILITIES DESCRIPTION

OFFSITES DESCRIPTION

PRODUCT EVACUATION SYSTEM

LOGISTICS

8. ENVIRONMENTAL CONSIDERATIONS

9.

10.

11.

12.

13.

PROJECT IMPLEMENTATION AND

SCHEDULE

PROJECT COST ESTIMATE

FINANCIAL ANALYSIS

HEALTH SAFETY AND ENVIRONMENT

RECOMMENDATIONS

ANNEXURE

1 OVERALL PLOT PLAN

2 SCHEMATIC FLOW DIAGRAM

3

EQUIPMENT LIST

Template No. 5-0000-0001-T2 Rev. 2/ 28.11.2014 Copyrights EIL – All rights reserved

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Executive Summary for DFR

Poly Propylene Unit of Numaligarh

Refinery Expansion Project (NREP)

NRL

SECTION 1.0

EXECUTIVE SUMMARY


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1.0 EXECUTIVE SUMMARY

1.1 Introduction

Numaligarh Refinery Limited (NRL) is planning to set up a Polypropylene Unit along with

its associated facilities at Numaligarh beside the existing refinery in the state of Assam to

meet the increasing demand of polypropylene in the North eastern region.

1.2 Background

Numaligarh Refinery Limited (NRL), a subsidiary of M/s OIL India Limited is a public sector

undertaking under the Ministry of Petroleum and Natural Gas. The refinery located at

Golaghat District in Assam was commissioned in the year 2000 with a crude processing

capacity of 3 million tonnes per annum (MMTPA) to process indigenous crude of Assam.

The refinery primarily produces MS & HSD conforming to BS-VI specification.

NRL is installing a parallel new refinery of crude processing capacity of 6 MMTPA to

expand its capacity from present 3 MMTPA to 9 MMTPA. The project is integrated with a

new crude oil pipeline from Paradip (Odisha) to Numaligarh (Assam) and a product pipeline

from Numaligarh to Siliguri where NRL has its own Marketing Terminal for distribution of

product. The crude oil considered for the design of new refinery train is Arabmix crude. MS

(Gasoline) & HSD produced from the new train shall meet the BS-VI specification. The

project has been named as Numaligarh Refinery Expansion Project (NREP).

Under this NREP project a high severity PFCCU unit with a capacity of 1.955 MMTPA is

being implemented. The LPG that will be generated in the high severity mode will contain a

significant potential of propylene which can be recovered for value addition. Potential exists

to explore the possibilities of setting up of a Poly-Propylene Unit to produce high value

polymers by considering feed stocks available from the refinery PFCCU.

Considering the above and in view of expected growth in demand for petrochemicals

products in India and to remain competitive in the market with products self sufficiency,

NRL planned to set up a PP Unit along with its associated facilities at Numaligarh beside

the NREP refinery.

NRL has entrusted EIL as a consultant to carry out the job of preparation of Detail

Feasibility Study for PP with cost estimate accuracy of ±20%.

For Estimating the capital investment within the accuracy of ±20%, preparation of DFR is

performed based on licensor input, in-house process data and year of expertise with in EIL.

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1.3 Project Objectives

The broad objectives of the Poly propylene unit of Numaligarh Refinery Expansion Project

are as follows:

PP unit Capacity: 360KTPA of homo polymer polypropylene production

Maximization of on-spec poly propylene product and minimize the transition time

in shifting between different grades of production.

Minimize hydrogen consumption

Minimise Capex through Integration of Streams

Maximise Return on Investment

1.4 Scope of Work

The scope of DFR is to estimate capital cost of the project with accuracy of ±20%, financial

analysis and schedule for overall project implementation to achieve the processing

objective. In addition environmental consideration, overall plot plan and implementation

philosophy for the project are also studied and included in the report.

Yield and utility estimate for the PP Unit is considered based on licensor input

supplemented with in-house data.

1.5 PP Unit Configuration with NREP

The Polymer Grade Propylene produced in the PRU section of the PFCC Unit of NREP is

further processed in the downstream unit i.e. PP unit to produce Homo-polymer grade

Polypropylene product.

Schematic diagram of integrated Polypropylene project with ongoing NREP is provided in

figure 1.1 below

Fig 1.1: Refinery Schematic Diagram

1.6 Basic Design Parameter

Basic Design parameters are summarized below:

PF

CC

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1.6.1. Feed Definition

Polymer Grade Propylene

Polymer grade propylene from PFCC unit has 99.6 wt% (min.) propylene and 0.4 wt%

(max) of propane.

Hydrogen Gas

Hydrogen Gas is available from existing hydrogen header of NREP.

1.6.2. Product Specification

The PP unit will be designed to produce four different grades of homo-polymer PP with the

MFI specification as per the table below:

Table 1.1: Different grades of Homopolymer produced in PP Unit

Sl.No. Description Specification

MFI (230 degC @ 2.16 kg), gm/10 min

1 Raffia Grade 3.4

2 Non–Woven Spun Bond Grade 38

3 Non-Woven Melt Blown Grade 100

4 Injection Moulding Homo-polymer

Grade

25

1.6.3. PP Unit Capacity

Polypropylene Unit design capacity is 360 KTPA of homo-polymer PP with an annual

product slate as per the table below:

Table 1.2: Annual slate of 4 different homo-polymers from PP Unit

Sl.No. Homo-polymer PP Grade description Annual Product Slate

(MT/Annum)

1 Raffia Grade 190000



4 Injection Moulding Homo-polymer Grade 55000

1.6.4. On-stream Hours

The stream hour considered for the study is 8000 hours per annum

1.6.5. Feed and Product prices

Feed, Product and utility prices which will be considered for the DFR are tabulated below:

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Table 1.3: Feed, Product & Utility Prices

Description Price, INR/Ton

Feed (5 years average price from April 2016 to March 2021)

Arab Light 31872

Arab Heavy 29902

Natural Gas 36487

VR of Existing Refinery 29735

Coker Distillate 32303

naphtha 35575

Product (5 years average price from April 2016 to March 2021)

LPG 38662

Poly Propylene 87041.0

BS VI Gasoline 43188

BS VI HSD 39496

RUF Bottoms to Ex Coker 24815

Sulphur 4744

Utility

Power Rs 6.5/ KWH

Treated Raw Water Rs 17.0/ m3

1.6.6. Case definition

Base Case: Base case corresponds to 6 MMTPA Refinery with PFCCU operating in low

severity mode and propylene produced from PRU is absorbed in the LPG product stream

and no propylene sale is envisaged. No Polypropylene unit.

Max Propylene + PP Case: Expansion case corresponds to 6 MMTPA Refinery with

PFCCU operating in propylene maximization mode or high severity mode and with Poly

propylene (PP) unit in operation. PP Unit taking feed propylene from upstream PFCC unit

and producing poly propylene which will be sold as final product

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1.7 Detail Feasibility Report- Key findings

1.7.1 Material Balance

Material balance for the base case and the expansion case which are considered for the

IRR estimation is provided in the table below:

Table 1.4: Material Balance of NREP integrated with PP

Description Base case, 6 MMTPA

refinery, KTPA

Max Propylene + PP case ,

6 MMTPA refinery + PP, KTPA

Feed

Arab Light 1800 1800

Arab Heavy 4200 4200

Natural Gas 468 473

VR of Existing Refinery 310 310

Coker Distillate 110 110

Naphtha 45.0 45.0

Total Feed 6933 6938

Product

LPG 674.0 496.0

Poly Propylene 0.0 346.0

BS VI Gasoline 1592.0 1518.0

BS VI HSD 3256.0 3160.0

RUF Bottoms to Ex Coker 555.0 555.0

Sulphur 145.0 145.0

Fuel and Loss 711 718

Total Product 6933 6938

1.7.2 Utility System

The utility requirements for the PP unit and its associated facilities have been worked out

based on licensor data and in-house estimate. Following utilities shall be required for the

PP Project -

Steam, DM, IA, PA, Nitrogen, Power, Raw water and cooling water

Following utilities shall be generated – Condensate, flare and effluent


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The utility summary for the PP project was shared with NRL and after detailed deliberation

it was concluded that all the above required utilities except for cooling water and power can

be met from the NREP utility system. Also all the utility streams generated can be

accommodated in the NREP utility system

Power for the PP project will be imported from grid, adequacy of the existing switch yard for accommodating this additional requirement have been confirmed by NRL. To cater to the cooling water demand new cooling water system is proposed. Following new utility system is proposed in the PP complex

Table 1.5: Utility System Details

Description Specifications Remarks

Cooling Water System

Cooling Tower Cells Capacity : 4000 m3/hr each

Number : 2w+ 1 s

New cooling tower along with

new re-circulating cooling water

pump to meet the cooling water

demand of PP unit

Re-circulating Cooling

Water Pumps

Capacity : 4000 m3/hr each

Number : 2 w+1 s

Rest of the utilities as tabulated below shall be catered from the NREP utility system

Table 1.6: Utility System Details


Treated Raw Water System

Treated Raw Water Normal: 210 m3/hr

Peak :250 m3 /Hr

Demand to be met from the

NREP RWTP.

Demineralized Water System

DM Water Normal: 2 m3/hr

Peak : 95 m3/hr


NREP RODM

Nitrogen System

Nitrogen Normal : 990 Nm3/hr

Peak :3740 Nm3/hr


NREP Nitrogen Plant

Compressed Air System

Plant Air Normal : 340 Nm3/hr Peak : 1050Nm3/hr

Demand to be met from the NREP Compressed Air system

Instrument Air Normal: 1300 Nm3/hr

Steam and Power System

Power Normal: 26 MW Demand to be met from Grid

LP Steam Normal: 12.5 TPH Peak:16.5 TPH

Demand to be met from NREP utility Boiler

MP steam Normal: Nil Peak: 9 TPH

HP steam Normal : 1.05 TPH Peak: 1.7 TPH


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MP BFW Normal: 0.5 TPH Peak: 1 TPH

Flare System

Flare Peak: 130TPH To be connected to NREP flare header

Effluent Treatment

Effluent 50 m3/hr To be routed to NREP ETP

Condensate

Suspect condensate Normal: 12.5 TPH Design: 13.9 TPH

To be routed to NREP CPU

Pure condensate Normal: 1.05 TPH Peak : 4 TPH

To be routed to NREP CPP

1.7.3 Offsite Storage Facilities

The offsite facilities are divided into two sections:

Feed/ Intermediate storage and transfer

Finished Product storage and transfer

1.7.3.1 Feed/ Intermediate Storage and Transfer

PPU receives polymer grade propylene as feed from the upstream PFCC unit. Normally,

PPU will receive 100 % of feed directly from the PFCC unit. However, in case of

emergency shutdown of the PP Unit, provision has been kept to store polymer grade

propylene in the offsite storage. Three (3) no. of mounded bullets (MB) each with a

pumpable capacity of 1620 MT have been considered for storing propylene. Three (3) days

of storage requirement have been considered while working out the bullet capacity.

List of Mounded Bullets for Polymer Grade Propylene storage is provided in Table 1.7 below:

Table 1.7 Polymer Grade Propylene Mounded Bullet Summary

Mounded Bullet Service

Bullet Pumpable Capacity

No of Bullet

Diameter Height Remarks

Propylene 1620 MT 3

8 m 80 m 2 working + 1 spare

1.7.3.2 Finished Product Storage & Transfer

The objective of providing product storage is to ensure receipt of unit rundown, testing of

product, and evacuation of on-spec product to consumer end. Additionally this will also

help to ensure availability of product in case of emergency shutdown of unit or continued

running of unit in the event of interruption in product transfer or dispatch for a period. The

PP is produced in pellet form and is stored in warehouse before dispatch. The warehouse

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will be sized corresponding to twenty one (21) days of storage requirement corresponding

to 100% throughput of the unit.

1.7.4 Land Requirement

The proposed PP unit will be set up at a Green field land located at North side of the

Numaligarh Refinery. The proposed site is well connected by road network and rail

network. The proposed PP plant will be integrated with NREP complex

Total plot area required for the PP Unit and its associated facility is 348093 SQM. Of this,

Plant area is 232821 SQM and Green belt area is 115272 SQM (>33 % of total area).

The PP Product will be evacuated via truck from the north side of the plot through a 3.5 km

road which connects to the nearest national highway.

1.8 Economic Evaluation for the PP Project

The financial results for the PP Project (based on 5 years average price) is worked out and

tabulated below:

Table 1.8 Financial evaluation

Note-1: Differential Opex = Expansion Case Opex- Base case Opex

Note-2: Differential Sale Revenue = Expansion Case Revenue- Base case Revenue

Sensitivity Analysis

Sensitivity analysis has been carried out to check the impact on Internal Rate of Return

(IRR) considering changes in capex, opex and GRM. IRR for all these cases habe been

tabulated below:

Description Cost

Rs. Crore

Capital Cost with Financing

Charges 4515.00

Differential Variable Operating

Cost 320.98

Fixed Operating Cost 197.87

Total Operating Cost 518.85

Differential Sales Revenue 1624.68

IRR Results (Revamp Case) IRR Before Tax IRR After Tax

IRR on Total Capital 20.57% 18.24%

IRR on Equity 25.56% 21.52%

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Table 1.9: Sensitivity analysis for 5 years average price of feed and product:

1.9 PROJECT SCHEDULE AND IMPLEMENTATION PLAN

The implementation schedule for the subject project has been established based on

following considerations:

1. Zero Date of the Project is considered as receipt of Licensor BEDP

2. Mechanical completion of the PP complex is considered as 36 months from the zero

date. Pre Commissioning & Commissioning activities will be done progressively as

indicated in the schedule.

3. EPCM Mode of execution is considered

4. It is considered that construction water and power will be considered from NREP

source

5. Environmental Clearance (EC) is considered under NRL scope and shall be

available on start of site enabling/ grading action.

Description IRR Before Tax IRR After Tax

On Total Capital

Base Case 20.57% 18.24%

Capex +10% 18.80% 16.73%

Opex +10% 19.98% 17.75%

Sales +10% 23.34% 20.61%

On Equity

Base Case 25.56% 21.52%

Capex +10% 22.21% 18.66%

Opex +10% 24.44% 20.58%

Sales +10% 31.08% 26.19%

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1.10 HEALTH, SAFETY AND ENVIRONMENT

1.10.1 Health and Safety

In order to ensure identification of any hazards associated with the project, which could

adversely affect the health and safety of personnel both within and outside the complex,

and the environment, a sound Health, Safety and Environment (HSE) policy is proposed to

be adopted during the course of project execution with primary objectives as under .

a) Provide clearly defined safety system goals for the design aspects of the project.

b) Ensure a safe working environment for all plant personnel.

c) Through intrinsic safety in design, eliminate the potential for occurrence of

hazardous scenarios that can result in injuries, environmental damage, business

interruptions or loss of assets.

d) Minimize the risk and consequences of an accident which cannot be eliminated

by intrinsic safety in design.

e) Maintain satisfactory means of escape and evacuation from any conceivable

incident.

f) Minimize the potential for pollution of the environment from accidental spills,

venting or flaring of hazardous materials.

In order to ensure the above, it is proposed to carry out the following HSE related studies

during the engineering stage:

- Hazard identification (HAZID) study

- Hazard and Operability Study (HAZOP)

- Quantitative Risk Assessment (QRA) Study

- Hazardous Area Classification

Other health hazards that are proposed to be studied are as follows:

a) Lighting

b) Noise

c) Thermal Environment

1.10.2 Environment

Wastes are streams that are not produced for sale or internal consumption. Some of

these wastes may be toxic, poisonous, flammable and harmful to the environment.

Hence, it is of utmost importance that the wastes generated are disposed off safely.

When waste production cannot be avoided, the following design principles shall be

adopted to achieve environmental compliance:

a) Minimise the waste generation

b) Safe disposal facilities within development boundary

c) Safe disposal facilities outside the unit.

Wastes generated are of three types:

a) Solid

b) Liquid


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i. Aqueous

ii. Non-aqueous

c) Gaseous

i. Point source gaseous emissions

ii. Fugitive emissions

Adequate care will be taken in process design to minimize the quantity of waste

produced. In addition, solid, liquid and gaseous wastes generated from various

processes in the refinery will be handled in a manner that minimizes their impact on the

environment.

1.11 SOCIO-ECONOMIC BENEFITS

The proposed project would generate some direct and indirect employment

opportunities during construction and operation phases, which will benefit the local

people. A significant nos. of manpower is required during construction and operation.

Local skilled and unskilled labour will be provided employment during construction and

operation phase. Tentative employment of skilled/unskilled workforce during

construction phase will be around 1750. Improvement in the overall socio-economic

status of the vicinity of project area, in the thematic areas of health, education, livelihood

and infrastructure is expected.

1.12 RECOMMENDATION

Based on the analysis detailed out in the previous sections, the following is concluded:

The project having capital cost of Rs 4515 Crores (with accuracy of ±20% and valid as of

Oct 2021) can achieve viability with a return of 18.24% post tax based on the product

prices.

Setting of PP Project, for which NRL has land in possession as well as its good

connectivity to the existing refinery for feed and utilities, proximity to highways and

ease of getting environmental clearance, will meet the petrochemical demand of

north eastern region which is expected to grow in future.

Also Polypropylene complex will accelerate development of downstream petrochemicals

industry for polymer processing like packaging, fibre and filament, automotive, health care

and personal care.

The development of clusters of small and medium industrial units associated with

petrochemical industry will not only improve the general infrastructure by improvement of

roads, education and health facilities but also generate tremendous employment

opportunities. This project will thereby improve the economic status of the people in the

area surrounding the Refinery/ petrochemical hub.

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The Economic analysis portrays a robust and attractive rate of return for refinery

configuration with PP, this is primarily due to the high value polymer product. Hence it is

recommended that since the PP project results in a significant return on investment, same

can be taken forward for implementation.

Considering the high IRR, the pre-project activities may be taken up on immediate basis

after having internal approval within NRL. This will give an opportunity to NRL to almost

match PP Project with the implementation of existing NREP project and realise the full

potential of PFCCU from day one, ensuring high profitability.


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Introduction for DFR



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SECTION 2.0

INTRODUCTION


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2.0 INTRODUCTION

Numaligarh Refinery Limited (NRL), a subsidiary of M/s OIL India Limited is a public

sector undertaking under the Ministry of Petroleum and Natural Gas. The refinery located

at Golaghat District in Assam was commissioned in the year 2000 with a crude

processing capacity of 3 million tonnes per annum (MMTPA) to process indigenous crude

of Assam. The refinery primarily produces MS & HSD conforming to BS-VI specification.

Further Numaligarh Refinery Limited (NRL) is implementing a parallel new refinery of

crude processing capacity of 6 MMTPA to expand its capacity from present 3 MMTPA to

9 MMTPA.

The project is integrated with a new crude oil pipeline from paradip (odisha) to

Numaligarh (Assam) and a product pipeline from Numaligarh to siliguri, where NRL has

its own marketing terminal for distribution of product. MS(Gasoline) & HSD produced from

the new train shall meet the BS-VI specification. The project has been named as

Numaligarh Refinery Expansion Project (NREP).

Under this NREP project a high severity PFCCU unit with a capacity of 1.955 MMTPA is

being implemented. The LPG that will be generated in the high severity mode will contain

a significant potential of propylene which can be recovered for value addition. Potential

exists to explore the possibilities of setting up of a Poly propylene Unit to produce high

value polymers by considering feed stocks available from the refinery PFCCU.

Considering the above and in view of expected growth in demand for petrochemical

products in India and to remain competitive in the market with product self-sufficiency,

NRL intends to explore the feasibility of putting up a PP unit in the refinery complex from

Polymer grade propylene feed from PFCC unit along with associated utilities and offsite

facilities.

The Polypropylene Unit is to be designed as a single train with a capacity of 360,000 TPA

of Homo-polymer grades of Polypropylene (PP) product with a target annualized product

split discussed elsewhere in the report. The capacity stated is inclusive of off spec (low

value) products produced during transition from one grade to another.

NRL engaged EIL as a consultant for selection of process licensor for new poly-

Propylene Unit (PPU), conduct a detailed feasibility study with cost estimate accuracy of

±20% and review of Licensor’s Basic Engineering & Design Package (BEDP) of PPU.

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Scope for DFR



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SECTION 3.0

SCOPE


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3.0 SCOPE

For the present Poly Propylene Unit of Numaligarh Refinery Expansion Project (NREP),

following activities shall be performed by EIL in line with agreed Scope of Work.

3.1 Licensor Selection

EIL shall select Process Licensor for the Polypropylene unit (PPU).

3.2 Detailed Feasibility Report (DFR)

Apart from the licensor selection activity, EIL shall also prepare the Detailed Feasibility

Report for this project to estimate capital cost of project with accuracy of ± 20%, financial

analysis and tentative schedule for overall project implementation to achieve the objective

of setting up a new Poly Propylene Unit of 360KTPA along with associated utilities offsite

facilities. This part of EIL’s scope of services shall include the following activities:

a) Design basis finalization for DFR

b) Preparation of project description, process description, and process flow schematic of

the new process unit.

c) Establishing utility requirements for the proposed project based on licensor’s utility

summary

d) Preparation of cost estimate with ±20 % accuracy.

e) Financial analysis (IRR Computation)

f) Preparation of project schedule

g) Preparation of suggested plot plan

h) Assessment of tankages/ ware house requirement for immediate and final products

i.e. propylene, poly-propylene etc

i) Assessment of OSBL facilities including dispatch facilities for PP products

j) The DFR report will consists of the following:

1. Executive summary

2. Introduction

3. Scope of work.

4. Design basis

5. Market Study

6. Project location

7. Project Description

8. Process Description of new process Unit

9. Overall Material balance

10. Utilities and Off-sites facilities assessment.

11. Capital Cost Estimate with ±20% accuracy.

12. Financial and sensitivity analysis

13. Detailed Project Implementation Plan and Schedule

14. Environmental considerations

15. Conclusions and Recommendations

16. Overall Plot Plan


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3.3 Review of Licensor’s BEDP for (PPU)

EIL shall associate with NRL/Licensor during preparation of Process Package by Licensor.

EIL’s broad scope of services for review of licensor’s BEDP shall be as under:

a) Preparation of Design Basis (Part A) for PP Unit.

b) Finalization of design basis for PPU Part A and Part B with Licensor, Part B as

obtained from NRL.

c) Review of PFD & Material Balance

d) Participation in PFD review meeting.

e) Review of Equipment layout

f) Participation in P&ID review meeting.

g) Review of P&ID, equipment datasheets, instrument datasheet, control scheme,

cause & effect diagram, utility, chemical and flare load summary

h) Resolution of licensor queries during licensor package preparation

i) Compilation of process package.


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Design Basis for DFR



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SECTION 4.0

DESIGN BASIS


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4.0 DESIGN BASIS

Design basis, considered for preparation of DFR for setting up a new Poly Propylene unit and

its required associated facilities at Numaligarh Refinery for NRL , is detailed below.

4.1 Basic Design Parameter

Study to be done by EIL DFR FR Other

Project Execution Methodology LSTK CONV

√ HYBRID

Project Duration Required In

Months

48 Months from the selection of EPCM consultant

and 36 months from the receipt of Basic Engineering

Design Package. BEDP is considered to be received

within 12 months of selection of EPCM consultant.

Of the 12 months, 6 months have been considered

for Licensor selection of PP unit followed by 6

months for receipt of BEDP form Licensor.

4.2 Other Studies

1

Market survey/study report (Demand and

supply analysis)

Excluded from present job scope.

2 Rapid Environmental impact study Excluded from present job scope.

3 Site evaluation/selection Greenfield site located adjacent to the

existing Refinery.

Site evaluation/selection is excluded from

present job scope.

4 Evaluation/Selection of licensors Included in present job scope.

5 Rapid Risk analysis Excluded from present job scope.

6 Soil investigation Excluded from present job scope.

7 Hydrological survey Excluded from present job scope.

Contour survey Excluded from present job scope.

Route survey (for transport of ODC materials

from various ports / industrial areas of the

country.)

Excluded from present job scope.

Marine Survey-effluent dispersion study Excluded from present job scope.

8 Health assessment /inspection reports

(For Revamp)

Not applicable

9 Downtime assessment report (For Revamp) Not applicable


Document No.

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Rev. No. B

Page 3 of 15




NRL

4.3 Plant Location

Village Nearest City (Kms) State Nearest Railway Station (kms)

Ponkagrant

Village

Golaghat (25 Kms) Assam Furkating Jn, 35 km from NRL

4.4 Land availability details

Plot Area

1. Soil investigation, site details

like Extent/cost of land filling/

piling data, if available may be

furnished

Greenfield land adjacent to existing Refinery Complex. Soil

investigation is excluded from present Job scope. Land

cost shall be excluded from DFR cost. Only site

development cost to be included.

2. Land Availability Greenfield land adjacent to the existing refinery complex.

Land availability for the PP and its associated facilities is

confirmed by NRL.

3. Rerouting Requirement

Rerouting of any existing

facilities like road, power lines,

drains etc. required/ not required

(if required, details of the same

may be furnished)

Not applicable.

Greenfield land adjacent to existing Refinery Complex

4. Grid Power Availability The Captive Power Plant of the Refinery will be saturated

post refinery expansion. Hence, incremental power

requirement for the PP unit and its associated facilities

shall be sourced from grid.

Nearest Dist Level

4.5 Raw Material

Name/Composition Polymer Grade Propylene: 99.6 wt% min.

Detailed feed composition is provided in Annexure 1.

Source Petro FCC Unit of NREP

Capacity to be considered 360 KTPA

On stream Hours 8000 Hours/annum

Crude Assay Not applicable


Document No.

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Rev. No. B

Page 4 of 15




NRL

4.6 Products

Name Homopolymer Poly Propylene product with an annual production

split as follows:

1. Raffia grade : 190 KTPA

2. Non-woven spun bond grade: 90 KTPA

3. Non-woven melt blown grade: 25 KTPA

4. Injection moulding-Homopolymer grade: 55 KTPA

Feed, Product and Utility price is provided in Annexure 2.

Annual Capacity

Market Place (preferred)

4.7 Plant Units

Process

Units

Capacity Utilities to be

generated

Capacity Catalyst / chemicals

Name Quantity Unit Rate

Poly

Propylene

Unit

360

KTPA

Cooling water

(Note 1)

8000 m3/hr

(Note 1): It is envisaged that some utilities like steam, fuel, DM water, BFW, condensate,

Treated Raw water, Instrument Air, Plant Air, Nitrogen required for the PP complex shall be

completely met from the refinery existing facilities, for others like cooling water new utility

facilities shall be required in the PP complex to cater to the incremental requirement.

Additional power shall be imported from Grid.

4.8 Offsite, Raw Material/ Product & Other Storage

Offsite, raw material/ product and other storages (Note 2)

Raw Material Intermediate Products Finished Products

Name

State

Liquid/

solid

No of

days of

storage

Name

State

Liquid/

solid

No of days

of storage:

Name

State

Liquid/

solid:

No of days

of storage:

Polymer

Grade

Propylene

(Note 1)

Liquid 3 days

PP Solid

21 days

Note 1: Details of mounded bullets considered for propylene in the NRL PP project is provided in

Annexure 3.

Note 2: Storage facility for intermediate products (i.e. Propylene bullets) and storage

requirement for the final product(i.e. PP warehouse) shall be located in the new land.

B

B


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NRL

4.9 Product Evacuation By Railway / Truck / Pipeline

PP dispatch facilities shall be considered as per NRL requirement.

Product

Name

% of product to

be moved by rail

% of product to

be moved by

road

% of product to

be evacuated

through Pipeline

% of product to be

evacuated through Coastal

movement sea tankers.

PP (89%) (11%)

NA NA

Length of rail to be laid/ distance between plant and railway siding NIL

Details of any major crossing (river/road/rail) coming on the way to

Railway station to be considered as part of Project cost.

NIL

4.10 Utilities

New utility systems are envisaged for the Refinery complex. Details of new systems are

discussed below.

4.10.1. Raw Water For Plant Operation

Source As per existing refinery

Distance from river/sea As per existing refinery

Raw water Analysis (if available) As per existing refinery

4.10.2. Electric Power For Plant Operation

Source Grid import

Volts 6.6 KV

Frequency 50 Hz

Rate Rs./kWH 6.5

Distance ____________ km from

Back up source of Power Not applicable

Level of Generation Not applicable

Contract Demand Charges Not applicable

Energy charges Not applicable

Minimum energy charges (as % of

Contract Demand)

Not applicable

In case this is not available, whether a

system is to be designed/included in

execution

Not applicable

4.10.3. Construction Power

Available Yes

Volts 415 V

KM away Within existing refinery.

Rate (Rs./KWH)

B


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NRL

Contract Demand Charges Power available within the existing refinery

shall be used as construction power Energy charges

Minimum energy charges (as % of

Contract Demand)

4.10.4. Construction Water

Available Yes.

KM away Within existing refinery.

4.10.5. Cooling water New facilities will be considered for the PP

complex within the Refinery area.

4.10.6. Nitrogen system To be met from existing refinery

4.10.7. Air system To be met from existing refinery

4.10.8. Steam system To be met from existing refinery

4.10.9. DM Water To be met from existing refinery

4.10.10. Condensate system To be met from existing refinery

4.10.11. Flare To be accommodated in existing refinery

4.10.12. ETP To be accommodated in existing refinery

4.10.13. Sour Water Stripping Units Not applicable

4.10.14. Amine Recovery Unit (ARU) Not applicable

4.11 Environmental Requirement

4.11.1 Effluent Specifications

Liquid Effluent MINAS Standards.

Gaseous Effluent MOE&F guidelines / APCB

Standards.

Solid Waste As per CPCB/APCB requirements

Stack height (Limitation to be specified) As per CPCB / APCB

requirements

– No nearby Airbase / airports.

Location of effluent discharge

& its distance from B/L of plant

As per existing refinery

Note: Details to be furnished below in case State Pollution Board specifications exist

4.11.2 Green Belt Requirement*

As advised by State Government during site

selection visit.

Proposed site would be in the newly

acquired land by NRL adjacent to

existing refinery site.

Green belt requirement shall be as

per MOE&F norms.


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NRL

* In absence of this data 100 M all around shall

be included.

4.11.3 REIA (In case of DFR) / Rapid Risk Analysis

(In case of FR)

Excluded in the present scope of

work

4.12 Building Required (Plant & Non Plant)

Name Type Area in M2

Administrative Building Existing facilities. To meet

Requirements of the PP

unit and its associated

facilities.

Warehouse(Chemical,

Spares, Product, Cement)

New warehouse for PP product shall

be considered.

Workshop Existing facilities.

Canteen New facilities.

Lab New facilities shall be considered.

Control room with rooms for

operating supervisors and

conference rooms

New facilities.

Training Centre Existing facilities.

Substations New facilities for PP and its

associated facilities shall be

considered.

Fire station New facilities shall be considered.

Operator Cabins New facilities.

Service Buildings New facilities.

Security Cabins New facilities.

Any other building as required SRR for PP and its associated

facilities.

Township – Existing facility. No augmentation of township due to the PP project is

considered.

% of staff to be provided accommodation

Health care facility Yes/No Existing facilities

School up to primary/secondary education Yes/No Existing facilities

Socio cultural facility Yes/No Existing facilities

Open space Yes/No NA

Commercial facility Yes/No Existing facilities

Provision for power, water and sewage

Disposal

Yes/No Existing facilities

Swimming pool Yes/No Existing facilities


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Rev. No. B

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NRL

4.13 Construction Aids:

Heavy crane to be purchased by owner No

(If yes, please specify capacity of range proposed and hiring

charges)

Capacity range ----N/A-------

Hiring charges -----N/A------

Whether Hydra, and medium size crane By erection contractor

(up to 35 Tons can be brought by Erection Contractor)

4.14 Project Cost Related Parameters

Expenditure Heads To be Included in report

Applicability of taxes & duties As per standard practice

Requirement of Piling As per standard practice

Land Cost Excluded.

Land Development Charges As per standard practice

Complex Boundary wall Excluded

Construction Period Expenditure As per standard practice

Dismantling cost of existing facilities

Not applicable. New greenfield

Plot

4.15 Owner Expenses During Project Implementation ..As considered in NREP FR (EIL Job No:B265)

Expenditure Heads To be Included in report

Expenses Towards Public Issue Yes

Salaries Yes

Perks And Facilities To Be Provided By Owner To People

Employed On This Job

Yes

Communication Yes

Travel Yes

Training Yes

Legal Expenses Yes

EPCM Fees Yes

Contingency Yes

Any Other

Total Amount For All The Above Heads Yes

B


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NRL

4.16 Additional Information, For Margin Money Calculation

Item Days

Salaries and wages and operating man-hours/manpower

envisaged

Refer Annexure 5

Repairs and maintenance spare inventory As per normal operating

requirement

Goods in process 4 days of sales

Finished goods 20 days of sales

Bills Receivable (Outstanding) 21 days of sales

Cash in hand 15 days of salary

Trade Credits 30 days of feedstock cost

Inventory level for Catalysts 7 days of catalyst cost

Inventory level for Chemicals 7 days of chemical cost

4.17 Information For Financial Analysis (To be read in conjunction with Annexure 4)

Project Funding % Grant -

Equity 30%

Debt 70%

Expenditure Pattern

(Grant Terms Required)

Equity before debt or concurrent 10% upfront

Equity,

subsequent

expenditure in

Debt Equity

Ratio

Equity Contribution % Promoter 100%

Financial Institution -

Public -

Debt Composition % Foreign

Currency

Financial Institutions 100%

Suppliers Credit -

Financial Institutions -

Rupee Portion Debentures to Financial

Institutions

-

Debentures to Public 100%

Terms and Conditions of

Debts / Debentures

From FII’s and

Suppliers’

Credits

(Foreign

Currency and

Rupee)

Front end processing fees 0.50%

Exposure fees -

Commitment fees -

Guarantee fees -

Interest Rates and Calculation

Methodology

8%

Loan

Repayment

Moratorium (from Commercial

Operations commencement)

12 Months


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Rev. No. B

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NRL

Terms Number of instalments 20 (5 Years)

Frequency of Instalments Quarterly

For Debentures

to Fis and

Public

Coupon rate -

Redemption Terms -

Interest rate on Short Term Loan 8%

Capacity Build-up 1st year 80%

2nd year 90%

3rd year 100%

Owner Philosophy for

Payment terms

Project Construction

period from zero date

to be counted from

Prices for feed, product, utility streams: To be considered as per Annexure 2.

Applicable Tax Benefits Will be provided during financial

appraisal analysis stage.

4.18 Key Considerations

1. Project cost estimate to be done with ±20% accuracy.

2. PP and its associated new facilities shall be located in a green field land adjacent to the

existing refinery.

3. The utility requirement for the proposed Poly propylene complex will be studied with respect to

the refinery utility system already envisaged in the new 6 MMTPA refinery complex. The

margins available in the refinery utility system capacity after meeting the refinery requirement

will be utilized for catering to the PP complex. It is expected that other than Cooling water all

other utilities like Steam, Condensate, DM water, BFW, Treated Raw water, Instrument air,

Plant air, Nitrogen, Effluent & flare shall be met from the existing NREP utility system, for

Cooling water new utility facilities will be envisaged in the PP complex to cater to the delta

requirement.

All the utilities except for power shall be met either from the Refinery utility system or from the

new utility system envisaged for PP. Power required for the PP complex shall be imported from

Grid

There will be a net increase of raw water intake to the Refinery due to the PP complex.

Adequacy of the existing RWTP and its pump capacity will be checked for the incremental

requirement.

Delta increase in the net power and water intake will be considered in the operating

expenditure.

4. The DFR cost estimate will include cost for the following facilities.


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NRL

i. Plant and Machinery cost for the Process units as listed below.

Sl. No Process unit Capacity,

KTPA

Licensor

1 Poly Propylene 360 Selection not yet completed

ii. Utility and Offsite facilities.

iii. Lab and Warehouse.

iv. SRR and sub stations.

v. Cost towards CSR and community development.

vi. Construction site requirement and Owner’s construction period expense shall be

considered in line with NREP FR (EIL Job no: B265).

vii. Start up and commissioning expense-as per standard practise.

viii. LF, BDEP fee and any other fee.

5. Cost towards the following heads will be excluded from the DFR cost estimate

i. Cost towards any Statutory clearance

ii. Any augmentation required in the existing refinery facilities

iii. Cost for market survey, EIA, RRA, Route survey, soil investigation.


Document No.

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Rev. No. B

Page 12 of 15




NRL

Annexure-1

Table 1.1: Polymer grade propylene composition

Component Specification Test Method

Propylene 99.6 wt.% (min) ASTM

D2163/D5273

Propane 0.4 wt% (max) ASTM D2712

Methyl-Acetylene 2 wt ppm (max) ASTM D2712

Propadiene 2 wt ppm (max) ASTM D2712

Methane 100 ppm vol (max) ASTM D2712

Ethane 200 ppm vol (max) ASTM D2712

Ethylene 10 ppm vol (max) ASTM D2712

Acetylene 2 wt ppm (max) ASTM D2712

1,3 Butadiene 3 wt ppm (max) ASTM D2712

Total C4´s 10 wt ppm (max) ASTM D2712

C5+ 10 wt ppm (max) ASTM D2712

H2 1 wt ppm (max) ASTM D2504

CO 0.03 ppm vol (max) ISO 6381

O2 1 wt ppm (max) ASTM D2504

COS 20 wt ppb (max) ASTM D6228

CO2 1 wt ppm (max) ISO 6381

Water 1 wt ppm (max) online

Ammonia 0.2 wt ppm (max) ASTM D5273

Total Sulphur 0.5 wt ppm (max) ASTM D6228

Arsine 20 wt ppb (max) By Licensor

Phosphine 0.03 ppm vol (max) By Licensor

Methanol 1 wt ppm (max) ASTM D4864

H2S 500 wt ppb (max) By Licensor

Hexane + Nonene 5 wt ppm (max) By Licensor

Cyclopentadiene 0.05 ppm vol (max) By Licensor

Isopropanol 1 wt ppm (max) By Licensor

Butenes 10 vol ppm (max) By Licensor

Pentenes 10 vol ppm (max) By Licensor

Inert (N2, CH4, C2H6, N-

Butane, I-Butane) 500 wt ppm (max) By Licensor

Non Condensables (N2,

NH3) 100 ppm vol (max) By Licensor

C4, C5 saturated 200 ppm vol (max) By Licensor


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NRL

Component Specification Test Method

hydrocarbons

Green Oil ( C8 – C12) 20 ppm vol (max) By Licensor

Oxygenated solvents

(methanol, ethanol,

propanol, acetone,

acetaldehyde)

10 wt ppm (max) ASTM D4864

Total non C3 unsat.

(Acetylene, Ethylene,

Methyl Acetylene,

Propadiene, Butadiene,

Butene)

50 wt ppm (max) By Licensor

Annexure-2

Table 2.1: Feed, Product and Utility prices

Streams UOM for

price

Price

Feed

Polymer grade propylene Rs/MT 55915.00

Product

Raffia grade Rs/MT 81500.00

Non-woven spun bond

grade

Rs/MT 85900.00

Non-woven melt blown

grade

Rs/MT 95000.00

Injection moulding homo

polymer grade

Rs/MT 85900.00

Utilities

Power Rs/Kwh 6.5

Treated Raw Water Rs/m3 17


Document No.

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Rev. No. B

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NRL

Annexure-3

Table 3.1: List of offsite tankages for PP

Sl. No Service Each Tank

capacity,

Pumpable, MT

No of Bullets Height/

Length, m

Dia, m Type

1 Propylene 1620 3

(2 w + 1 spare)

Note-1

80 8 Mounded

Bullet

Note-1: 3 Number of new propylene bullet each with capacity 1620 MT is considered, with 2

Working + 1 Spare operating philosophy which corresponds to 3 days storage requirement.

Annexure-4

Table 4.1: Information for financial analysis

1 Construction Period 36 months

2 Project Life 15 years

3 Loan Repayment period 5 years

4 Moratorium Period 1 Years

5 Interest on Long Term

Debt

12%

6 Capital Phasing (Total Capital)

1 Year 20%

2 Year 45%

3 Year 35%

7 Capacity Build – up

1st year 80%

2nd year 90%

3rd year onwards 100%

8 Corporate Tax Rate @ 22% X 1.10 X 1.04

9 MAT Not Applicable

B


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Annexure-5

Table 5.1: Manpower requirement

Management - Average salary is Rs. 38.17 lakhs pa.

Non Management - Average salary is Rs. 29.94 lakhs pa.

Unit Management Non Management

Number of Person Number of Person

PP 10 24

Cooling

tower/Offsite/Warehouse

7 12

Total 17 36

.


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 1 of 2

Market Study for DFR



NRL

SECTION 5.0

MARKET STUDY


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 2 of 2

Market Study for DFR



NRL

5.0 MARKET STUDY

This section is excluded from the report as per the scope of the work.


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 1 of 2

Project Location for DFR



NRL

SECTION 6.0

PROJECT LOCATION


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 2 of 2

Project Location for DFR



NRL

6.0 PROJECT LOCATION

The Proposed PP Unit will be set up at Greenfield land adjacent to the existing refinery

complex which is located in Ponkagrant Village at a distance from 25 kms from golaghat

city. The distance of the project site from nearest station/ port/ airport/ city is as given

below:

Furkating Railway Station : 35 km

Jorhat Airport: 44 km

Refer annexure -1 for overall plot plan of PP Unit and its associated facilities and Land

details required for PP Unit in table 6.1 below:

Table 6.1: Land Details

Total area, SQM Plant area, SQM Green belt, SQM

348093 232821 115272

Fig 6.1: Project location

B

TEMPLATE NO. 5-0000-0001-T2 REV. 2 / 28.11.2014 COPYRIGHTS EIL – ALL RIGHTS RESERVED

Document No.

B394-RP-79-41-0001

Rev. No. B

Page 1 of 5

Project Configuration for DFR



NRL

SECTION 7.1

PROJECT CONFIGURATION


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 2 of 5




NRL

7.1 PROJECT CONFIGURATION

The various facilities envisaged under this project are briefly explained in this section.

7.1.1 Integration of Polypropylene Unit with Existing Numaligrah Refinery Expansion Project

Under NREP a high severity PFCC unit with a capacity of 1.955MMTPA is being

implemented. The LPG that will be generated in the high severity mode will contain a

significant potential of propylene which can be recovered for value addition. The Polymer

Grade Propylene produced in the PRU section of the PFCC Unit is further processed in the

downstream unit i.e. PP unit to produce Homo-polymer grade Polypropylene product.

Schematic diagram of integrating Polypropylene project with ongoing NREP is provided in

figure 7.1.1 below:

Fig 7.1.1: Refinery Schematic Diagram

7.1.2 Basis of DFR

PPU capacity: 360KTPA

Turn Down ratio: The unit is capable of minimum turndown of 50% of design capacity

except for the extruder system for which minimum turndown ratio is 60%.

Feed to PP Unit

1) Polymer Grade Propylene from PFCC

Polymer grade propylene shall be made available from the refinery PFCC unit.

2) Hydrogen

Hydrogen Gas shall be made available from existing NREP header and to be utilized

in the polypropylene unit.

PF

CC


Document No.

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Rev. No. B

Page 3 of 5




NRL

Products Homo-polymer Poly propylene product with an annual grade split is as follows:

Sl.No. Description Annual Product Slate

(MT/Annum)

1 Raffia Grade 190000



4 Injection Moulding Homo-polymer

Grade

55000

Annual Product slate is inclusive of on-spec & off spec (transition) material generated.

By Products

1) Propylene Rich Purge Gas to PFCC

Propylene Rich purge gas from the PP unit is send to PFCC for the recovery of

propylene monomer.

On Stream factor : 8000 hrs /annum

7.1.3 Process Units

Design Capacities of Process units & Licensors names are listed in Table 7.1.1 below:

Table 7.1.1: Process Unit Capacities

Sl No Process unit Design Capacity, KTPA

1 Poly Propylene 360

7.1.4 Utilities System

Major utility systems which shall be implemented as part of the PP project are tabulated in

Table 7.1.2 below.

Table 7.1.2: Utility System Details


Treated Raw Water System

Treated Raw Water Normal: 210 m3/hr

Peak :250 m3 /Hr


NREP RWTP.

Cooling Water System

Cooling Tower Cells Capacity : 4000 m3/hr each

Number : 2w+ 1 s

New cooling tower along with new

re-circulating cooling water pump

to meet the cooling water demand

of PP unit


Water Pumps

Capacity : 4000 m3/hr each

Number : 2 w+1 s

Demineralized Water System

DM Water Normal: 2 m3/hr

Peak : 95 m3/hr


NREP RODM

Nitrogen System

B


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NRL


Nitrogen Normal : 990 Nm3/hr

Peak :3740 Nm3/hr


NREP Nitrogen Plant

Compressed Air System

Plant Air Normal : 340 Nm3/hr Peak : 1050Nm3/hr

Demand to be met from the NREP Compressed Air system

Instrument Air Normal: 1300 Nm3/hr

Steam and Power System

Power Normal: 26 MW Demand to be met from Grid

LP Steam Normal: 12532 kg/hr Peak:16532 kg/hr

Demand to be met from NREP utility Boiler

MP steam Normal: Nil Peak: 9000 kg/hr

HP steam Normal : 1050 kg/hr Peak: 1700 kg/hr

MP BFW Normal: 500 kg/hr Pea k: 1000 kg/hr

Demand to be met from existing

Flare System

Hydro Carbon Flare Peak: 130TPH To connected to NREP existing header

Effluent Treatment

Effluent 50 m3/hr To be routed to NREP ETP

Condensate

Suspect condensate Normal: 12532 kg/hr Peak: 13900 kg/hr

To be routed to NREP CPU

Pure condensate Normal: 1050 kg/hr Peak : 4000 kg/hr

To be routed to NREP CPP

7.1.5 Offsite Facilities

Summary of various offsite facilities envisaged are described below:

7.1.5.1 Intermediate Feed/ Product Storage and Transfer

1) Polymer Grade Propylene

3 number of propylene mounded bullets (new), having dimension of 80 m length and 8 m

dia. Each bullet is having pump able capacity of 1620MT

Out of the 3 mounded bullets 2 shall be in operation with one spare.

Table 7.1.3 List of Bullets for Propylene storage

S.No Bullet Capacity MT (Stored) No. of Bullet

Diameter , m

Height, m

Remarks

1 1620 3 8 80 New

This provides a total storage of approximately ~3 days operation based on the design

capacity of PP unit.

B

B

B


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NRL

Table 7.1.4 Propylene Transfer Pump

S.No.

Service

Rated Capacity (m3)/hr

Number

Type

Remarks

1. Propylene 115 2 (1w+1s)

Centrifugal (Vertical Can)

7.1.5.2 Finished Product Storage and Transfer

Blending, pellet storage facility and bagging section has been considered within the PP unit.

Product warehouse considered in OSBL is corresponding to 21 days storage.

7.1.6 Land Requirement

Total plot area required to accommodate proposed process units, offsites, utilities and other

infrastructure facilities, control room, electrical substation, mandatory green belt etc of this

project is 348093 SQM

7.1.7 Township

Existing facility of NREP, no augmentation on the township for PP project is considered.

B

B

B


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B394-RP-79-41-0001

Rev. No. A

Page 1 of 4

Process description for DFR



NRL

SECTION 7.2

PROCESS DESCRIPTION


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Rev. No. A

Page 2 of 4




NRL

7.2 PROCESS DESCRIPTION

7.2.0 Introduction

A brief process description along with a flow schematic for the polypropylene unit

envisaged is provided in this section.

7.2.1 Poly Propylene Unit

For typical scheme of PPU is provided in Annexure-2

Polymer grade propylene having 99.6 wt% of propylene and 0.4 wt% of propane is

provided from OSBL at 39 kg/cm2(g) and 40 deg C.

Polypropylene unit is divided in 8 sections i.e :

a) Propylene Purification Section

b) Hydrogen purification Section

c) Nitrogen Purification Section

d) Reaction section

e) Resin Degassing Section

f) Vent Recovery Section

g) Extruder and pelleting section

h) Pellet Conveying and homogenization section

A) Propylene Purification Section:

Facilities are provided to purify and pump propylene to reaction section. Traces

amount of components such as water; arsine, oxygen, CO2, CO, ammonia, alcohols

and ketones are reduced to acceptable concentrations in the propylene purification

system to avoid polymerization catalyst poisons. Purification section comprises of:

I. Propylene Arsine removal Vessel

II. Propylene Dryer: To remove water

III. Propylene CO Treater: To remove CO

IV. MAP Removal: To remove acetylene

V. Propylene filter

B) Hydrogen Purification Section:

Hydrogen is added to control the size of the polymer molecule and sets the MFR of

the final product. Low pressure Hydrogen is supplied from OSBL with a battery limit

pressure of 18 kg/cm²(g) and 45 deg C.

Facilities are provided to purify and compress hydrogen to reaction section. Traces

amount of CO, CO2 and water compounds poisons the polymerization catalyst. In

the purification system CO, CO2 and water is reduced to acceptable concentrations

in the purification system.


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NRL

C) Nitrogen Purification section:

Nitrogen is supplied from OSBL with a battery limit pressure of 4.0 kg/cm2(g) and at

amb. temperature. Facilities are provided to compress nitrogen and to fed reaction

section which is to be used during reactor shutdown and for designated high

pressure consumer.

Low pressure Nitrogen provided at Battery limit is used for regenerable bed treaters

i.e Hydrogen dryer, Propylene Dryer and CO removal bed. Following major

equipments are provided in the nitrogen purification section:

I. Nitrogen compressor

II. Nitrogen Heater : To heat Nitrogen during regeneration of dryer beds

III. Nitrogen Filter

D) Reaction section :

Fresh propylene is fed to the reactor along with the required catalyst, co-catalyst,

hydrogen and stereo-modifier (donar) for production of four different grades of

homopolymer i.e

I. Raffia Grade : Annual production 190KTPA (*)

II. Non-woven spun Bond grade : Annual Production 90 KTPA (*)

III. Non-woven melt blown grade : Annual Production 25 KTPA (*)

IV. Injection Moulding homopolymer grade : Annual Production 55KTPA (*)

(*)Quantity specified above including off-spec (transition) material generated.

The reaction take place in a gas phase reactor, the heat of polymerization is

removed by evaporative cooling supplied by liquid propylene feed. Reaction gas is

continuously removed from the top of the reactor. Reactor overhead vapor (“Recycle

Gas”) is partially condensed and recycled backed to the reactor. The products are

discharged from the reactor to the resin degassing section.

E) Resin Degassing Section :

A mixture of entrained hydrocarbons and nitrogen separates from the resin in the

resin degassing section. The un-reacted monomer and nitrogen from degassing

vessel top is sent to the vent recovery section for separation of un-reacted monomer

and nitrogen.

F) Vent Recovery Section

Un-reacted monomer from the degassing section is further compressed and Nitrogen

is separated from un-reacted monomer by using propylene as a refrigerant.

Recovered nitrogen rich stream is further used as a conveying gas. Un-reacted

monomer recycled back to the reactor and a part of un-reacted stream which is rich

in propylene content is send to PFCC for propylene recovery.


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NRL

G) Extruder and pelleting section

The main flow of granular resin, solid additives and liquid additive from the resin

additive handling system are fed to the extruder. In the extruder the polymer powder

together with solid additives is melted and homogenized through the shear induced

by the co-rotating intermeshing screws.

Gases, nitrogen and devolatilized hydrocarbons are vented from the extruder. The

melt then enters the underwater pelletizer through a die plate where rotating knife

blade cut the melt into pellets. The pellet water slurry is pumped into an agglomerate

remover and pellet dryer. The water returns to the pellet water system consisting of a

pelleting water tank, a pelleting water pump and a pelleting water cooler.

Losses from the pellet water loop are compensated with demineralized water. The

dry pellets are screened (removal of possible oversize pellet agglomerates or

undersize pellets) and pneumatically conveyed to the pellet blending silos for

homogenization.

H) Pellet Conveying and homogenization section

Within the pellet pneumatic conveying system, pellets are conveyed by air in a

conveying system that is suitable to minimize dust and angel hair formation during

the conveying process. The air compressors supply the air for:

• pneumatic conveying of pellets from extrusion to blending silos

• pneumatic conveying of pellets from blending silos to bagging units

• blending air and purge air for homogenization silos

Conveying air is filtered before compression. Downstream of the compressors the air

is cooled. Condensed water is separated, and the air is again filtered.

Within the pellet homogenization process, polymer pellets are homogenized by re-

circulating the pellets around the pellet blending silos. In addition, the silos are

designed with internals that permit pellets to flow at different rates within the body of

the silo. This ensures a homogeneous blend of pellets at the silo discharge point.

Pellets from the blending silos are conveyed to the bagging system. Pellets from the

blending silos are fed by conveying air to the elutriator. Air for elutriators is supplied

by elutriator blower which is equipped with elutriator blower filter. Pellets flow by

gravity via elutriator rotary feeders to the pellets bagging lines and storage.


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Rev. No. B

Page 1 of 4

Material Balance for DFR



NRL

SECTION 7.3

MATERIAL BALANCE


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Rev. No. B

Page 2 of 4




NRL

7.3.1 MATERIAL BALANCE

The material balance for the 6 MMTPA refinery with and without Poly Propylene (PP)

unit is compared below.

Table 7.3.1: Material Balance

Description Price,

INR/Ton

Base case, 6

MMTPA refinery,

KTPA

(Note 1)

Max Propylene +

PP case,

6 MMTPA refinery

+PP, KTPA

(Note 2)

Feed

Arab Light 31872 1800 1800

Arab Heavy 29902 4200 4200

Natural Gas 36487 468 473

VR Of Existing Refinery 29735 310 310

Coker Distillate 32303 110 110

Naphtha 35575 45.0 45.0

Total Feed 6933 6938

Product

LPG 38662 674.0 496.0

Poly Propylene 87041.0 0.0 346.0

BS VI Gasoline 43188 1592.0 1518.0

BS VI HSD 39496 3256.0 3160.0

RUF Bottoms To Ex Coker 24815 555.0 555.0

Sulphur 4744 145.0 145.0

Fuel and Loss

711 718

Total Product 6933 6938

Note 1: Base case corresponds to 6 MMTPA Refinery with PFCCU operating in low

severity mode and propylene produced from PRU is absorbed in the LPG product stream

and no propylene sale is envisaged. No PP unit.

Note 2: This case corresponds to 6 MMTPA Refinery with PFCCU operating in propylene

maximization mode or high severity mode and with Poly propylene (PP) unit in operation.

PP taking feed propylene from upstream PFCC unit and producing poly propylene which

will be sold as final product.

B

B


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NRL

7.3.2 Product Pattern

A comparison of product yield (wt %) and products’ percentage contribution in sales

revenue (%) with and without PP unit provided below:

Fig 7.3.1: % Product Yield without PP Unit

Fig 7.3.2: % Product Yield with PP Unit

B


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NRL

Fig 7.3.3: Product contribution in sales revenue without PP Unit (%)

Fig 7.3.4: Product contribution in sales revenue with PP Unit (%)


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Rev. No. B

Page 1 of 11

Utilities Description for DFR



NRL

SECTION 7.4

UTILITIES DESCRIPTION


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Rev. No. B

Page 2 of 11




NRL

7.4.0 Utility System Facilities

This section gives the Utility requirement for the new facilities envisaged in this DFR.

While most of the utility demand for the PP complex shall be met from the NREP existing

utility system, for the rest new dedicated utility system shall be installed in the PP complex

at adjacent to the location of the NREP, Numaligarh Assam.

The Normal and peak utility requirement for the PP complex has been identified and

presented in the following sections.

The broad details of the utility systems are identified in this section. A suitable overdesign

margin has been considered to arrive at the system. This design margin is provided to

take care of the uncertainties in the utility consumption figures that are estimated in the

DFR and shall be firmed up/validated during detailed engineering. Utility consumption

figures have been arrived at considering the requirements in process units, utility systems

and others (Offsite area, leakages, hose stations etc).

All analysis presented in this DFR is made on NORMAL utility consumption / generation,

unless specifically mentioned.

Utility consumption for the PP complex is tabulated in Table 7.4.1 below:

Table 7.4.1: Utility Requirements for PP complex

Utility Utilty Requirements

Treated Raw Water,m3/h 210

Re-Circulating cooling water,m3/hr 6780

Instrument Air Nm3/hr 1300

Plant Air, Nm3/hr 340

Nitrogen, Nm3/hr 990

DM Water, m3/hr 2

HP Steam , TPH 1.05

LP Steam, TPH 12.53

Power (MW) 26

MP BFW, TPH 0.5

Pure Condensate generated ,TPH 1.05

Suspect Condensate generated, TPH 12.53

Cooling water Blow-down, m3/hr 50

Effluent ,m3/hr 50

Flare Peak Load ,TPH 135

Brief write up for each utilities are given in the following sections.

7.4.1 Treated Raw Water System

Treated Raw water for the PP complex will be provided from existing NREP treated raw

water header.


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NRL

Fig 7.4.1: Typical Scheme of Treated Raw Water System

7.4.1.1. Treated Raw water Requirements of the PP complex

The estimated treated water requirement for various purposes in the complex is

summarized in the following table:-

Table 7.4.2: Treated Raw Water Consumption

S.No Unit Normal

m3/hr

Maximum

m3/hr

1. Cooling water Make up 205 244 (Note-1)

2 PP Unit 5 6

Total Treated Raw Water Demand; m3/hr 210 250 (Note-2)

Notes:

1. Maximum cooling water makeup corresponds to the installed capacity of the cooling

tower.

2. Maximum raw water demand is considering 20% Design margin on normal raw

water requirement. This will also take care of the maximum requirement of any of

the above stream at a time along with the normal requirements of other streams.

7.4.2 Recirculating Cooling Water System

Cooling water, an essential utility in process units is required to remove heat from process

fluids for cooling.

A typical scheme of re-circulating cooling water system is shown in figure below

Fig 7.4.2: Typical Scheme of Recirculating Cooling Water System

PROCESS UNITS

PROCESS UNITS

Cooling Tower

Re-circulating CW pumps


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NRL

The cooling water requirements of the PP Unit and associated facilities will be met

through separate re-circulating cooling water systems operating with treated raw water as

makeup. Cooling water requirement for all the facilities in the PP complex will be entirely

met through one new cooling water systems as mentioned below:-

Cooling water system (Cooling tower): This cooling water system will meet total cooling

water demand of PP unit and its associated facilities such as Lab, PP Substation, and PP

SRR. The cooling water system includes cooling towers, cooling water circulating pumps,

cooling water treatment facilities viz. chemical dosing for quality control, Sulphuric acid for

pH control etc. and other auxiliary items.

The make-up water for the cooling water system shall be taken from the NREP existing

treated raw water system header.

7.4.2.1. Cooling water requirement of the PP Complex

The normal consumption of cooling water in the PP Unit and its associated facility are as

follows:

Table 7.4.3: Cooling Water Requirement

Case Cooling Water Requirement

(m3/hr)

PP 6480

Lab 100

PP S/S 100

PP SRR 100

Total 6780

Total with 10% over design margin 7458

To meet the CW requirement of the complex, quantity as tabulated above, the following

set of equipments have been envisaged as part of the CW system design.

Table 7.4.4: Cooling Water System Configuration

Equipment

Description

Capacity of each

item Quantity required

Cooling Tower System

Cooling Tower

Cell 4000 m3/hr 2W+1S

Cooling water

Pump 4000 m3/hr 2W+1S

Additionally, suitably sized auxiliaries like formulation dosing system, biocide dosing

system, sulphuric acid dosing system, chlorinator, Polymeric Dispersant dosing system,

side stream filter, etc. will be provided.


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NRL

7.4.3 Steam, Power and BFW System

7.4.3.1 Power demand for the PP complex

Power is used in the PPU Unit and its associated facility mainly for the following main

purposes:

a) For driving motors to run various rotating machinery (pumps, compressors,

blowers, etc.) in the complex

b) For meeting the power demand of instruments in the entire complex

c) For operating electric heaters (like instrument air dryer heater, electric tracing of

lines if specified, etc.)

d) For plant lighting and other miscellaneous purposes, etc

Tables below give the power requirement of various units/ facilities in the PP complex:

Table 7.4.5: Power demand (Note-2)

Units/Facilities Capacity, Net Power Consumption, KW

(Note-1)

PP 360 KTPA 23000

Cooling tower 8000 m3/hr 1900

Miscellaneous 1000

Total 26000

Notes:

1. Power demand is based on utility data available in licensor proposal or licensor utility

summary and considering sufficient margin over the licensor data to meet the detail

engineering requirement.

2. The power demand shall be imported from the grid.

7.4.3.2 Steam demand for the PP complex

Tables below give the steam requirement at various levels

Table 7.4.6: Steam demand at various levels

Sl.No. Description Net Steam Demand (TPH)

Normal Peak

1 HP steam 1.05 1.7

2 MP Steam 0 9

3 LP Steam 12.53 16.53

The above Steam demand shall be met from the NREP refinery steam header.

7.4.3.3 Boiler Feed Water demand for the PP complex

Tables below give the BFW (MP) requirement of PPU unit


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NRL

Table 7.4.7:MP Boiler Feed Water (Note-1)

Description Normal

(TPH)

Peak

(TPH)

MP BFW 0.5 1

Note-1: The BFW demand shall be met from the NREP BFW system

7.4.4 DM Water System

DM water for the PP Unit and its associated facility is required for the following purposes:

- As process water for dilution, under water pelletizer and washing

Demand of DM water shall be met from the existing NREP header.

7.4.4.1. DM water Demand of the PP Complex

The estimated DM water requirements of various process units & utilities area are as

given in the following Table:-

Table 7.4.8: DM water requirement

Unit Capacity

KTPA

Continuous Demand,

M3/HR

Note-1

Intermittent demand,

M3/HR

Note-1

Poly Propylene

Unit

360 2.0 95 Start-up filling of

pellet water tank

Total 2 95

Notes:-

1) Continuous & intermittent requirement are based on licensor utility summary.

7.4.5 Condensate System

Steam is being used in the complex as process steam, motive fluid for steam turbine

drives, ejector, heating etc. Condensate results from the steam reboilers, condensate

steam drives etc. Within PP unit, suspect and pure condensate will have segregated

collection system. During normal operation, the suspect condensate and tracer

condensate shall be send to existing Centralized Condensate Polishing Unit (CPU) in

NREP. However, the pure condensate shall be normally routed to existing pure

condensate header in NREP.

The condensate being generated which shall be recovered, can be categorized under

following headings:

a) Pure Condensate: This is condensate produced by a source where the possibility

of contamination by leakage across the heat transfer surface is minimal. This is

ascertained by comparing the process and steam side operating pressures for the

exchanger. If the process side operating pressure is lower than the steam side

operating pressure, possibility of contamination of condensate produced with


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NRL

process fluid is minimal and the condensate produced from such a source is

deemed ‘pure condensate’.

b) Suspect Condensate: This is condensate produced by a source where the

possibility of contamination by leakage across the heat transfer surface exists. This

is ascertained by comparing the process and steam side operating pressures for the

exchanger. If the process side operating pressure is higher than the steam side

operating pressure, possibility of contamination of condensate produced with

process fluid exists and the condensate produced from such a source is deemed

‘suspect condensate’.

c) Surface Condenser Condensate: Condensate produced by the surface condenser

of a condensing type steam turbine is normally considered as pure.

d) Tracer / Traps Condensate: Condensate produced by the tracing is suspect

condensate.

Condensate generation summary for the complex is as given here under:

Table 7.4.9: Suspect Condensate

Description Suspect Condensate ,TPH (Note-2)

Normal Peak


Total 12.53 13.9

Table 7.4.10: Pure Condensate

Description Pure Condensate TPH (Note-1,3)

Normal Peak


Total 1.05 4.0

Notes: 1. Pure condensate is produced from Extruder Barrel.

2. Suspect condensate generated from the PP complex shall be routed to NREP

Condensate polishing unit.

3. Pure condensate generated from the PP complex shall be routed to NREP Power

plant,

7.4.6 Compressed Air And Nitrogen System

Compressed air is required in the complex for the following main requirements:

As Instrument Air to operate the various instruments in the facility and also for the

purging of some control panels

As Plant Air is used for scouring air for side stream filters of cooling water systems,

etc.

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NRL

Compressed air required for all of the above uses is generated at a centralised location in

the plant and distributed to the various users through headers. Two qualities of

compressed air are produced and distributed:

Plant Air comprising compressed air cooled to ambient temperature. This air, though

not containing any entrained water droplets, is saturated with water vapour at the

supply conditions.

Instrument Air comprises compressed air cooled to ambient temperature and dried

to remove water vapour to meet stringent atmospheric dew point requirements.

This system will be designed to supply compressed air to the various users at the required

conditions, quality and quantity.

There will be a common plant air header & common Instrument air header from NREP

Compressed Air System to various process and utility areas.

During a power failure, to enable the safe shutdown of PP Unit, facilities will be provided

to supply emergency instrument air for up to 30 minutes

7.4.6.1 Total Air requirement for the PP complex

The compressed air requirements of the PP complex work out to be as follows:

Table-7.4.11: Total Air (Note-3)

Description Normal (Nm3/hr)

Maximum (Nm3/hr)

Instrument Air (Note-1) 1300

Plant Air (Note-2) 340 1050

Note:

1 Normal

2 Normal Flow is based on considering 2 hoses operating simultaneously and peak

flow is based on air scouring of cooling tower side stream filter.

3 The Instrument Air and Plant Air demand of PP unit and its associated facility is met

from existing header of NREP.

7.4.6.2 Nitrogen system

High purity Nitrogen is required in the PP Unit and associated facility for the following

purposes:

(A) Continuous requirement

Blanketing of surge drums and storage tanks

Purging of compressor seals, flare header purging etc.

(B) Intermittent requirement

Purging of systems during start-ups and shut-downs

Absorbant/ Adsorbant Regeneration

7.4.6.3 Nitrogen requirements of the PP complex

The table below gives the continuous and intermittent consumptions of PP Complex


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NRL

Table 7.4.12: Nitrogen requirement

Unit Capacity, KTPA

Continuous Demand, Nm3/hr

Intermittent demand, Nm3/hr (Note-1)

PPU 360 990 5570

Total 990 5570

Notes:

1. Normal nitrogen requirement is 990 Nm3/hr. Additionally 4580 Nm3/hr is required for

intermittent basis for the following scenario i.e.

Dryer and absorbant re-generation

Back up HP Nitrogen for Reaction section

Start-up purge Nitrogen for reactor after seed is charged

Normal nitrogen requirement shall be met from the gaseous nitrogen produced from

the NREP N2 Plant and Intermittent requirement shall be met through liquid

nitrogen storage and gaseous nitrogen.

7.4.7 Fuel System

No fuel requirement for the NRL PP Project

7.4.8 Flare system

The flare system will be provided for safe disposal of combustible, toxic gases which are

relieved from process plants and off sites during start - up, shutdown, normal operation or

in case of an emergency such as:

Cooling water failure

General Power failure

External fire case

Any other operational failure

Blocked outlet

Reflux failure

Local power failure

Tube rupture

The refinery complex shall have single flare systems, for Hydrocarbon flare for process

units & off-sites handling hydrocarbon and the other for the sulphur block handling sour

flare.

The HC flare from the PP Unit has one independent flare header and shall be connected

to existing flare header of NREP.

B

B


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Rev. No. B

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NRL

7.4.8.1 Hydrocarbon flare load from PP Complex

Given below is the flare load from the PP Unit

Table 7.4.13: Design HC flare load

Relief Scenario, LP Flare Load (kg/hr) Mol.wt Temp. oC

Cooling water Failure 130000 41 45

7.4.9 Air conditioning requirement

Air conditioning system shall be considered in the following facilities

Polymer lab

Canteen

Control room

Satellite Rack Room (SRR)

Fire and safety Building office rooms

All field operators cabins in the process area

Ware house office rooms

Security office for visitors pass at entrance gate

Admin Buliding

Substation (SS)

New Air conditioning system shall be considered in the PP Complex. Centralized Vapour

Absorption Refrigeration (VAR) unit systems in the PP complex with chilled water

network to individual local Air Handling Units (AHUs) are considered to cater to the Air

Conditioning requirements of the PP complex. However, in addition to the centralized

VAR system, some additional standalone AC system for buildings shall be considered

where VAR is not feasible.

7.4.10 Brief specification of Electric Equipments

(A) Emergency Power requirement for PP complex

Emergency power are considered for the compressor Lube oil package, MOVs, Fire

water pump, Lighting, communication system, Hazard detection and signalling etc.

The emergency power required for the PP complex is 750 KW. This emergency

power requirement shall be met from the new emergency generator set in the

Substation of NRL PP complex. The emergency generator set will start

automatically on power failure and feed the selected loads. It shall be capable of

taking care of the load variations (e.g. the starting of the largest rated motor with

specified base load).

(B) Plant Address System

It shall consist of Central exchange(s)/ Distributed intelligent nodes, Master control

station(s) with inbuilt loudspeaker, microphone, Desk type call stations with inbuilt

microphone, loudspeaker for installation in buildings, wall/ column mounting type call

stations for hazardous/ safe areas with external loudspeaker as per Operational

requirements, Flashing beacon for noisy areas.

B


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NRL

(C) Fire Detection & Alarm System

The Fire Detection and Alarm System shall be an independent, micro-processor

based Analogue Addressable system comprising of individual break glass type

manual call points, automatic sensors e.g. smoke/heat detectors, hooters, exit signs,

Main DGFAP, battery, battery charger and other hardware. The system shall be

designed to provide audio-visual indication at the main fire alarm panel to be located

in fire station and zonal panels.

The fire detection system shall be interfaced with fire suppression system, HVAC

system, pressurization system, plant communication system and any other systems

as required.

7.4.11 Fire Protection & Fire water system

The Fire Protection system shall be conceived to operate both in prevention and fighting

mode, depending on the relevant actions selected, either manual or automatic.

The fire fighting system shall be designed & provided as per OISD 116 as follows:

Fire Water system (including Hydrants, monitors, HVLRM, automatic spray

system on process equipments)

Clean Agent System for Control room/SRR

DCP extinguishing system for catalyst/TEAL storage area as per NFPA 17

CO2 extinguishing system as per NFPA 12

Automatic Water spray system in product warehouse

HV spray system on transformers

Portable extinguishers

Mobile fire fighting system

For fire water system, tapings (minimum two number) shall be taken from the existing

fire water network of NREP to cater to the fire water demand of PPU. The NREP fire

water system is designed for fighting two major fires and same is adequate to cater to

the fire water demand of PPU facilities.

Pressure available at tap off point of pp unit (in blocked case) is considered as 9.5 bar

(g).

B


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Rev. No. B

Page 1 of 3

Offsite description for DFR


Expansion Project (NREP),

NRL

SECTION 7.5

OFFSITE DESCRIPTION


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Rev. No. B

Page 2 of 3




NRL

7.5 OFFSITE SYSTEM

7.5.1 Intermediate feed storage and pumping

This section describes the storage and pumping facilities of feed/intermediate and

finished product based on the annual production of 360 KTPA of homo-polymer grade

PP. The storage of intermediate and finished products of homo-polymer grade PP. The

offsite facilities are divided into two sections:

Feed/ Intermediate storage and transfer

Finished Product storage and transfer

7.5.2 Intermediate Feed Storage and Transfer

Intermediate storage has been provided to take account of turnaround, interruption

(including emergency), catalyst regeneration & replacement etc. Intermediate unit feed

flow control will be within the respective unit. Intermediate feed storage mounded bullets

is considered based on 2 days intermediate storage basis.

7.5.2.1. Propylene Storage and Transfer

PPU receives polymer grade propylene as feed from the upstream PFCC unit.

Propylene shall be treated in the Propylene treating section of the PPU to remove

impurities such as Moisture, MAP, CO arsine etc from polymer grade propylene and

shall be converted to polypropylene in the polymerization section of the PPU. Normally,

PPU will receive 100 % of feed directly from the PFCC unit. However, in case of

emergency shutdown of the PP Unit, provision has been kept to store polymer grade

propylene in the offsite storage. Accordingly 3 days storage has been considered for

propylene. Three (3) no. of mounded bullets (MB) each with a pumpable capacity of

1620 MT have been considered for storing propylene.

The bullets and pumps considered for selected case are mentioned below.

1) The three (3) new propylene bullets of pumpable capacity of 1620 MT each shall be

used to store polymer grade propylene

2) Two pumps (one operating one standby) shall be considered each with a rated capacity

of 115 m3/hr for transferring of polymer grade propylene from the bullet to PP battery

limit.

Table 7.5.1: Polymer Grade Propylene Mounded Bullet Summary

Mounded

Bullet Service Bullet Pumpable

Capacity No of Bullet

Diameter Height Remarks

Propylene 1620 MT 3 (Note-1)

8 m 80 m 2 working + 1 spare

Note 1: All the 3 new bullets are considered in NRL PP complex.

B

B

B


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NRL

Table 7.5.2: Propylene Pump Summary

S.No. Service Rated Capacity (m3)/hr

Number Type Remarks

1. Propylene Transfer Pump

115 2 (1w+1s) Centrifugal

(Vertical Can type)

1w+1s

7.5.3 Finished Product Storage and Transfer Philosophy

The objective of providing product storage is to ensure receipt of unit rundown, testing

of product, and evacuation of on-spec product to consumer end. Additionally this will

also help to ensure availability of product in case of emergency shutdown of unit or

continued running of unit in the event of interruption in product transfer or dispatch for a

period. The bagged PP product shall be stored in the warehouse, which will be sized

corresponding to ~21 days of storage requirement of corresponding to 100%

throughput of the unit.

7.5.4 Man Power Requirement

With the implementation of the new PP project, the complexity of the NREP will increase. Therefore, to strengthen the organization, NRL has recommended manning levels to reflect an effective operations and maintenance that would be required to support the normal operation of the refinery.

For the PP Project Unit operation, the manpower strength required will be a total of 53 persons in various categories, break provided below:



Total 17 36

B

B


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B394-RP-79-41-0001

Rev. No. B

Page 1 of 2

Product Evacuation System for DFR


Refinery Expansion Project (NREP),

NRL

SECTION 7.6

PRODUCT EVACUATION SYSTEM


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 2 of 2

Product Evacuation System for DFR


Refinery Expansion Project (NREP),

NRL

7.6 PRODUCT EVACUATION FACILITIES

This section describes the evacuation facilities of finished products from Polypropylene

unit of NREP. This chapter focuses on the mode of transfer of the finished products and

the facilities associated for evacuation.

7.6.1 Product evacuation

All different grades of homo-polymer shall be dispatched by road from PP unit at

NREP complex to different customers. The different grades with annual capacity are

tabulated below:

a) Raffia Grade 190 KTPA

b) Non-Woven Spun Bond grade 90 KTPA

c) Non-Woven Melt Blown grade 25 KTPA

d) Injection Moulding Homo-polymer grade 55 KTPA

7.6.2 Bagging Facility

90% of product shall be bagged in 25 kg bags and 10% in 1000 kg Flexible Intermediate

Bulk Container (FIBC).Bagging operation should be considered during the period from

6AM to 10 PM i.e 16 hours per day bagging with 12hrs of effective bagging time is

considered.

7.6.3 Product loading in ware house

Bagged product from bagging machine is stacked in the ware house with the help of fork

lift. From the ware house stacked bags of final product is loaded in the truck at loading

station and send to various consumers by road.

Following assumptions are considered for truck loading and unloading facility:

Truck loading/ unloading will take place in only day time 7 hrs/day

Truck Capacity 16 Tons/truck

No. of trucks loading/unloading per station 2 trucks/ station

Time for loading/unloading in 1 station 1 hrs/ station

Table 7.6.1: Truck loading arrangement

Sl.No. Description

1. PP Evacuation 1080 TPD

2. Tons per shift for truck loading (effective 7 Hrs) 1080 Tons

3. Tons per hour available for truck loading per shift ~160 TPH

4. No. of truck required for loading per hour 10 trucks

5. No. of trucks loading station required 8

8 no. of truck loading station & 10 trucks for loading per hour is envisaged for NRL PP Unit.

B

B

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Page 1 of 2

Logistics for DFR



NRL

SECTION 7.7

LOGISTICS


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 2 of 2

Logistics for DFR



NRL

7.7.0 LOGISTICS

This chapter deals with the movement of polymer grade propylene from NREP complex

to PP Unit and finished Homo-Polymer PP grade products outside the refinery.

7.7.1 Polymer Grade Propylene

Polymer Grade propylene produced from PFCC of NREP is fed to PP unit. Intermediate

Storage capacity of 2X1620MT of polymer grade propylene is provided for PP unit.

Three (3) new propylene bullets are envisaged for PP Unit in the complex with 2 working

+1 stand by philosophy.

7.7.2 Finished solid products

All four grades of homo-polymer polypropylene are supplied in pellet form and packed in

25kg bags or in 1000 kg Flexible Intermediate Bulk Container (FBIC). These polymer

bags placed in pallets are stored in the warehouse and are transported via truck by road

to the designated consumers.

8 no. of truck loading station with 2 trucks loading in 1 station is envisaged for NRL PP

Unit

7.7.3 Utilities

All utilities required for the PP plant shall be met from the NREP utility system except for

Cooling water and power. New cooling tower is envisaged to cater the PP demand.

Power will be ingested from the grid.

Power

The total power demand of PP Complex i.e. 26 MW shall be met from the grid. No

separate facility for power generation is envisaged for the PP Unit.

Treated Raw Water

Total Treated raw water required for PP unit and cooling tower (make water) is 210m3/hr

(Normal) and 250m3/hr (Design). The required amount of treated water is met from

existing RWTP in NREP complex. The raw water pump which is used to pump raw water

to RWTP and the raw water treatment plant is adequate to cater this increased 250

m3/hr flow required for PP Unit as confirmed by NRL.

B

B

B


Environmental Consideration for DFR



NRL

Document No.

B394-RP-79-41-0001

Rev. No. B

Page 1 of 15

SECTION 8.0

ENVIORNMENTAL CONSIDERATIONS





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Document No.

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Rev. No. B

Page 2 of 15

8.1. Pollution Control Measures

All applicable environmental standards prescribed by Ministry of Environment, Forest &

Climate Change (MoEF&CC) and Central Pollution Control Board (CPCB) shall be applicable

to this project. Various pollution control measures required to meet the prevailing

environmental standards are planned for each case at the different stages of execution of the

project, viz., design, construction and operational phases.

8.2. Indian Environmental Legislation

Government of India has made many legislations/rules for the protection and improvement of

environment in India. Various environmental legislations/rules applicable to the proposed

project facilities are as follows.

- The Environment (Protection) Act, 1986, amended up to 1991

- The Environment (Protection) Rules, 1986, amended upto 2008, schedule 1, s.no.3

- Environment (Protection) Third Amendment Rules, 2002

- Environment (Protection) fifth Amendment Rules, 2009, schedule VI, part D, Item III,

s.no.6

- Environment (Protection) Amendment Rules, 2012

- Coastal Regulation Zone-Notification dated 18th January, 2019.

- The Public Liability Insurance Act, 1991, amended 1992

- The Public Liability Insurance Rules, 1991, amended 1993

- The Water (Prevention and Control of Pollution) Act, 1974, as amended up to 1988.

- No. 19 of 2003, [17/3/2003] - The Water (Prevention and Control of Pollution) Cess

(Amendment) Act, 2003.

- The Water (Prevention and Control of Pollution) Rules, 1975

- The Water (Prevention and Control of Pollution) Cess Rules 1977 as amended up to

1992

- The Water (Prevention and Control of Pollution) Cess Rules 1978 as amended up to

1992.

- The Water (Prevention and Control of Pollution) Amendment Rules, 2011.

- The Air (Prevention and Control of Pollution) Act 1981, as amended up to 1987.

- The Air (Prevention and Control of Pollution) (Union Territories) Rules, 1983

- Hazardous Wastes (Management and Handling) Rules, 2008, amended up to 2009.

- Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 (Amendment)

Rules, 2000.

- Noise Pollution (Regulation and Control) Rules, 2000, amended up to 2010.

- Common Hazardous waste Incinerator rules, The Environment (Protection) Rules, 1986,

amended up to 2008, schedule 1, s.no.100.

The proposed Polypropylene project of NRL shall be designed taking into account the

above-referred legislations/rules and as per the directives of Environmental Clearance

documents. Besides this the proposed effluent and emission standards will also be compiled

for this Project.

http://www.google.co.in/url?q=http://moef.nic.in/assets/513e.pdf&sa=U&ei=KSqsUbz6BY7SrQf2uYDQAg&ved=0CBoQFjAA&usg=AFQjCNEPMOz9XKI0f6wbysrudvQUYvoN3A

http://www.moef.nic.in/legis/water/wc_act_03.htm

http://www.moef.nic.in/legis/water/wc_act_03.htm

http://envfor.nic.in/downloads/rules-and-regulations/gsr830-831-e.pdf





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Document No.

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Rev. No. B

Page 3 of 15

A brief description of the environmental protection measures proposed to be adopted in the

project with respect to the various components of the environment like air, water, noise, land,

ecology etc., are given in the subsequent sections.

8.3. Pollution Control Measures

In order to minimize the impact of the project on the environment, due attention is being

given for implementing effective pollution control measures. The design stage endeavors to

mitigate the problems related to health, safety and environment at the process

technology/source level itself. The design basis for all process units lays special emphasis

on measures to minimize the effluent generation at source.

During the operation of the plant, the major areas of concern will be stack emissions and

fugitive emissions of hydrocarbons from the process units and storage tanks along with

disposal of treated effluent. Handling, treatment and disposal of hazardous wastes will also

be an area of concern.

The specific control measures related to gaseous emissions, liquid effluent

treatment/discharges, noise generation, solid waste disposal, etc., along with relevant

stipulated standards are described below:

8.4. Air Environment

The gaseous emissions from the proposed expansion project will be controlled to meet all

the relevant standards stipulated by the regulatory authorities. Standards applicable to this

project are classified into three categories:

Ambient Air Standards

Emission Standards

VOC control, Emission and Monitoring

8.5. Ambient Air Standards

The ambient air quality around the premises will be limited to those limits as per National

Ambient Air Quality Standards, which are given below in Table- 8.1.





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Page 4 of 15

Table 8.5.1: National Ambient Air Quality Standards 2009

S.No. Pollutants Time Weighted

Average

Concentration in Ambient Air

Industrial,

Residential, Rural

and Other Area

Ecologically

Sensitive

Areas (Notified

by Central

Government)

1.0 Sulphur Dioxide (SO2),

µg/m3

Annual Average* 50 20

24 hours** 80 80

2.0 Oxides of Nitrogen as

NO2, µg/m3


24 hours** 80 80

3.0 Particulate Matter (size

less than 10 µm) or

PM10 µg/m3


24 hours** 100 100

4.0 Particulate Matter (size

less than 2.5 µm) or

PM2.5 µg/m3


24 hours** 60 60

5.0 Ozone (O3), µg/m3 8 hours** 100 100

1 hour** 180 180

6.0 Lead (Pb), µg/m3 Annual Average* 0.5 0.5

24 hours** 1 1

7.0 Carbon Monoxide (CO)

mg/m3

8 hours** 2.0 2.0

1 hour** 4.0 4.0

8.0 Ammonical (NH3),

µg/m3


24 hours** 400 400

9.0 Benzene (C6H6), µg/m3 Annual Average* 5 5

10.0 Benzo (α) Pyrene

(BaP), Particulate

Phase Only ng/m3

Annual Average* 1 1

11.0 Arsenic (As), ng/m3 Annual Average* 6 6

12.0 Nickel (Ni), ng/m3 Annual Average* 20 20

* Annual Arithmetic mean of minimum 104 measurements in a year at a particular site

taken twice a week 24 hourly at uniform intervals.

** 24 hourly or 8 hourly or 1 hourly monitored values, as applicable shall be complied

with 98% of the time in a year. 2% of the time, it may exceed the limits but not on

two consecutive days of monitoring.

8.5.1 Emission Standards

Ministry of Environment, Forests & Climate Change (MoEF&CC) has issued Environmental

Standards for Petrochemical (Basic and Intermediates) Industry vide G.S.R. 820(E), dated

09/11/2012. Summary of these standards are given below.





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Parameter Limiting concentration in

mg/Nm3, unless stated

Existing

refineries

New

Plant/Expansion

of Existing Plant

Furnace,

Boiler,

Heater,

Vaporiser

Sulphur Dioxide (SO2)

Gas firing 50 5

0 Liquid firing 1700 8

5

0

Oxides of Nitrogen

(NOx)

Gas firing 350 2

5

0

Liquid firing 450 3

5

0

Particulate Matter (PM)

Gas firing 10 5

Liquid firing 100 50

Carbon Monoxide (CO)

Gas firing 150 1

0

0

Liquid firing 200 1

5

0

Notes: (i) All values shall be corrected to 3% Oxygen.

(ii) Wet scrubber shall necessarily be operated at the time of decoking.

(iii) Norms for CO shall be monitored only in case of Phthalic Anhydride (PA), Maleic

Anhydride (MA), Terephthalic Acid (PTA) and Dimethyl Terephalate (DMT) Plants.

Norms for CO emissions shall not be applicable to PA/MA manufacturing standalone

existing plants with an installed capacity of less than 30,000 metric tonnes per

annum, provided that such units have a chimney/stack of minimum 30 metres height

for emitting Carbon Monoxide.

Process Emission (Specific Pollutant)

Substance Source Concentration (mg/Nm3)

Existing

Plants

New Plants

Chlorine EDC/VCM plant & Incinerator 10 10

Hydrochloric acid mist EDC/VCM plant & Incinerator 30 30

Ammonia Waste water stripper, acyronitrile

plant, caprolactum plant

75 75

Hydrogen sulphide Naphtha pretreatment, olefin plant 05 05

Phosgene TDI and MDI plant 01 01

Hydrogen cyanide Acrylonitrile plant 10 10

VOC (HAPs)-TDI&MDI TDI, Methylenediphenyl,

diisocyante plants

0.1 0.1

VOC( HAPs ) Benzene

& butadiene

Benzene, Butadiene plants 5 5

VOC (HAPs)

EO,VCM,EDC<CAN,PO

EO,VCM,EDC,CAN,PO plants 20 10

Organic particulate PA, MA and TDI plants 50 25





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Process Emission (General Pollutant)

Source Limiting concentration

in mg/Nm3

VOC (MA, PA &Phenol) MA,PA,Phenol plants 20

VOC (EB, Styrene,

toluene, xylene,

aromatics, EG,PG)

Ethyl benzene (EB), Styrene,

Toulene, Xylene, Aromatics, EG,PG

plants

100

VOC (paraffin,

acetone,olefins)

Non methane, HC(paraffin), Acetone,

Olefins plants

150

NOTE.- HAP - Hazardous Air Pollutants are those pollutants that cause cancer or other

serious health effects, or adverse environmental and ecological effects.

Standards for Fugitive Emission:

Storage of Volatile Liquids: General Petrochemical/ Petroleum Products

1. Storage tanks with capacity between 4 to 75m3 and total vapour pressure (TVP) of more

than 10 kpa should have fixed roof with pressure value vent.

2. Storage tanks with capacity between 75 to 500 m3 and total vapour pressure (TVP) of 10

to 76 kpa should have internal floating roof or external floating roof or fixed roof with

vapour control or vapour balancing system.

3. Storage tanks with the capacity of more than 500 m3 and total vapour pressure (TVP) of

10 to 76 kpa should have internal floating roof or external floating roof or fixed roof with

vapour control system.

4. The tanks with the capacity of more than 75 m3 and total vapour pressure (TVP) of more

than 76 kpa should have fixed roof with vapour control system.

5. Requirement for seals in Floating Roof Tanks-

I.

(a) Internal Floating Roof Tank (IFRT) and External Floating Roof Tank (EFRT) shall

be provided double seals with minimum vapour recovery of 96%.

(b) Primary seal shall be liquid or shoe mounted for EFRT and vapour mounted for

IFRT. Maximum seal gap width will be 4 cm and maximum gap area will be 200

cm2/m of tank diameter.

(c) Secondary seal shall be rim mounted. Maximum seal gap width will be 1.3 cm

and maximum gap area will be 20 cm2/m of tank diameter.

(d) Material of seal and construction shall ensure high performance and durability.

II. Fixed roof tanks shall have vapour control efficiency of 95% and vapour balancing

efficiency of 90%.

III.

(a) inspection and maintenance of storage tanks shall be carried out under strict

control;

(b) or the inspection, API RP 575 may be adopted;





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Page 7 of 15

(c) In-service inspection with regard seal gap should be carried out once in every six

months and repair to be implemented in short time; and

(d) the possibility of on-stream repair of both shall be examined.

IV. Storage tanks shall be painted with white colour shade, except for derogation of

visually sensitive area.

Storage of Benzene, VCM and CAN

(i) FRT with vapour for incineration with 99.9% of removal efficiency for volatile organic

compounds (VOC) shall be provided; or

(ii) IFRT/EFRT with double seals, emission-reducing roof fitting and fitted with fixed roof with

vapour removal efficiency of at least 99% shall be provided; or

(iii) Internal floating roof and nitrogen blanketing in between fixed and floating roofs shall be

provided.

Emission control for Road tank truck/ Rail tank wagon loading

Gasoline and Naphtha:

(i) VOC reduction, %

or

(ii) Emission, gm/m3

(i) 99.5

or

(ii) 5

Benzene:


or

(ii) Emission, mg/m3

(i) 99.99

or

(ii) 20

Toluene/Xylene:


or

(ii) Emission, mg/m3

(i) 99.98

or

(ii) 150

General Standards for emissions from VOC (Petrochemicals)

Item Source Quantum limit in gm/hour

for new expansion plants

(gm/hr)

Organic Particulate Phthalic anhydride (PA), Maleic

Anhydride(MA), Toulene Diisocynate plants

process emission

,Toule (MA),

100

VOC-HAPs (TDI+MDI) Toulene Diisocynate TDI, Methylene diphenyl

diisocyante plants-process emission

0.5

VOC-HAPs (Benzene +

Butadiene)

Benzene, Butadiene Plants-Process

emission

25





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Rev. No. B

Page 8 of 15

VOC-HAPs

(EO,VCM,EDC,ACN,

PO)

EO,VCM,EDC,CAN,PO plants-process

emission

50

Abbreviations : EG-Ethylene Glycol, PG- Propylene Glycol, EO-Ethylene Oxide, VCM-Vinyl

Chloride Monomer, EDC-Ethylene dichloride, ACN-Acrylonitrile, PO-Propylene Oxide, HCN-

Hydrogen Cyanide

8.5.2 General Guidelines

1. Emission monitoring shall be carried out as per the Emission Regulations – Part III,

published by Central Pollution Control Board.

2. Following methods may be used for measurement of pollutant concentrations in the

emissions:

Table 8.5.2: Method of Measurement of emissions

S.

No.

Parameter Method of measurement

1 Sulphur Dioxide

(SO2 )

USEPA CFR – 40 Part 60 Appendix A Method 6

2 Oxides of Nitrogen

(NOx )


3 Particulate Matter

(PM)


4 Carbon Monoxide

(CO)

USEPA CFR – 40 Part 60 Appendix A Method

IOA/Combustion analyzer with NDIR

detector

5 Nickel + Vanadium

(Ni + V)


6 Hydrogen Sulphide

(H2 S)


(D) Guidelines for minimizing emissions from Flare

1. For each flare system it is necessary to establish the maximum quantity of waste gas,

which can be handled. It is also required to establish the minimum quantity of pilot and

purge gas to ensure safe, stable operation and readiness to take the maximum quantity

of waste gas. There is need to measure of pilot, purge and vent gas to the flare. The

composition and sulphur should be determined. After establishing base data, the

refineries should aim towards using essentially pilot and purge gases in the flare. Under

this condition the flare should be completely smokeless. The above may be achieved by

a combination of the following techniques:

(i) Reducing relief gas to flare by management/good housekeeping practices;

(ii) Balancing the fuel gas system;

(iii) Installing a gas recovery system;





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Page 9 of 15

(iv) Using high integrity relief valves; and

(v) Applying advanced process control

2. The flow rates of pilot, purge and vent gas to flare are to be monitored. Vent gas should

have on/off flow indicator in addition. The opacity of the flare is to be measured.

3. For normal to 20% of max flare capacity the flare should be smokeless. At higher

capacities low smoke is desirable. The flare system is to provide safe, reliable stand-by

system to meet short periods of venting due to start-up, shutdown and emergencies.

Pilot should be under monitoring and under continuous detection. Flare should be under

observation.

4. Quantity of gas vented to the flare should be reported. The periods of venting should be

recorded and target is to have it for less than 5 minutes in consecutive two hours and 24

hrs in a year. Noise level is to be measured and reported.

5. The heights of various stacks will be determined taking into consideration the "Guidelines

for Minimum Stack Height" as per notification by MoEF&CC dated 19th May 1993, which

fixes the minimum stack height based on emission of Sulphur Dioxide. This is as given

below:

H = 14(Q) 0.3

Where H = Stack Height in m,

Q = Sulphur Dioxide emission in kg/hr.

If, the Pollution Control Board specifies any minimum stack height, the higher of the

two will be selected. However, restriction imposed by Civil Aviation Department shall

also be considered.

8.5.3 Gaseous Effluents Generated From Pp Plant

Major Gaseous Emissions will be Process Waste Gas from silos, tanks, Pelletisation/

Extruder area, Polymerisation Reactor etc. These gases will be vented to atmosphere after

meeting the Environmental standards.

8.6. Noise Environment

The following Noise sources will be part of the proposed project:

Extruder Gears and Motors

Recycle Gas Compressors

Powder and Pellet Conveying Compressors

Carrier Gas Compressors

All noise sources exceeding the noise standard will be encapsulated. It is further

recommended to separate extruder motors and gear boxes by a brick wall from the extruder

on the ground level of the extruder building. All mentioned compressors will either have a

noise hood each or they will be placed in a common hood. Personnel working in such noise

areas have to wear the relevant noise protection equipment.

At the boundary of the proposed plant, Ambient Standard for Noise, specified by CPCB as

given below in Table-8.6.1 shall be met.





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Page 10 of 15

Table 8.6.1: Ambient Air Quality Standards in respect of Noise

S. No. Area Code Category of Area Limit in dB (a) Leg

Day Time Night Time

1.0 A Industrial area 75 70

2.0 B Commercial area 65 55

3.0 C Residential area 55 45

4.0 D Silence zone 50 40

Notes : 1. Daytime is reckoned in between 6 am and 9 pm

: 2. Night time is reckoned in between 9 pm and 6 am

: 3. Silence zone is defined as areas upto 100 meters around such Premises as

hospitals, educational institutions and courts. The Silence zones are to be

declared by the competent authority.

: 4. Mixed categories of areas should be as "one of the four above Mentioned

categories" by the competent authority and the Corresponding standard shall

apply.

The following measures for noise control will be followed at the design stage:

- Noise level specification of various rotating equipment as per Occupational Safety

and Health Association (OSHA) standards.

- Equipment layout considering segregation of high noise generating sources.

- Erecting suitable enclosures, if required, to minimize the impact of high noise

generating sources.

8.7. Water Environment

Several measures are proposed to be incorporated at the designs stage towards minimizing

the generation of wastewater and treatment of the generated effluent. Some of these

measures are described below:

Closed blow down system will be incorporated for hydrocarbon liquid discharges in

all the process units, which will reduce the wastewater load to ETP both in terms of

quantum load and quality. This is another of the in-plant control measures.

Appropriate segregation and collection philosophy (separate sewers for

process waste, contaminated rainwater, spent caustic, cooling tower blow down,

boiler blow down etc.) will be incorporated for various effluents depending on

individual stream characteristics.

A comprehensive wastewater management system to comply with treated effluent

quality for disposal as specified by CPCB (as per The Environment (Protection)

Rules, 1986) shall be established.

Process area will be paved to avoid contamination of soil/sub-soil/ground water in

case of accidental spill/leakage of hydrocarbon liquids.





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Table-8.7.1: Standard for liquid effluent Discharge for Petrochemicals (Basic &

Intermediates) Industry

S. No. Parameter Limiting value for

concentration (mg/l, except for

pH)

1 PH 6.0 – 8.5

2 [*BOD (3days at 27°C)] 30 3 **Phenol 5

4 Sulphide (as S) 2

5 COD 250 6 Cyanide ( as CN) 7 ***Fluoride (as F) 8 Total suspended solids 100 9 Hexavalent Chromium (as CR+6)] 0.1

11 ****Total Chromium (as CR) 2.0

Notes:

*State Board may prescribed the BOD value of 30 mg/l if the recipient system so demands.

** The limit for phenol shall be conformed to at the outlet of effluent treatment of phenol

plant. However, at the final disposal point, the limit shall be less than 1 mg/l.

*** The limit for fluoride shall be confirmed to at the outlet of the chrome removal unit.

However, at the disposal point fluoride concentration shall be lower than 5mg/l.

**** The limits for total and hexavalent chromium shall be conformed to at the outlet of the

chromate removal. This implies that in the final treated effluent, total and hexavalent

chromium shall be lower than prescribed herein.

8.8. Waste Water Generated From PP Plant

The wastewater generation from the proposed project will be mostly Intermittent liquid

effluent streams containing White Oil/TEA/Atmer/IPA/other organic components. A

continuous liquid effluent having various organic components like Acetone, Isopropanol,

Tert-butanol will be generated from Phase Separator Process which will have very less flow.

These waste water streams along with non-process effluents like floor wash, contaminated

rain water will be sent to existing ETP of NREP and treated there. The concentrated organic

components and PP powder will be thermally incinerated. 50 m3/hr of Cooling tower blown

down will be routed to existing RO-DM plant of adjacent NRL refinery for treatment and

reuse. Condensate generated will also be recovered.

8.9. Land Environment

During the design stage itself due care will be taken to select the process technologies

generating minimum solid wastes so that their handling, treatment and disposal do not cause

any serious impact on the existing land environment. Also, efforts will be made to recycle

some of the spent catalysts & PP solid powder by way of returning to the original supplier for

reprocessing.





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The solid wastes management plan proposed is briefly described below. The provisions of

Hazardous Waste (Management & Handling) Rules, 1989 and its subsequent amendments

will be complied with.

The following wastes will be generated:

1. Solid waste from PP Plant

2. General Solid Wastes

Solid waste from PP Plant:

Spent Adsorbents Spent Filter Bags, Filter elements etc. will be sent to secured landfill for

disposal. Spent Catalyst will be sold to the recyclers.

General Solid Wastes

Non‐hazardous, non‐recyclable solid waste consisting of waste refractory, spent insulation,

used filter cartridges, spent charcoal, spent clay and sand will be generated. These wastes

will be disposed off in landfill.

8.10. Provision Of Green Belt

A green belt of appropriate width needs to be provided around the plant. This green belt will

help to reduce the noise and visual impact upon the surrounding population as much as

possible. Green belt area considered for PP complex is 115272 SQM which is >33% of the

total plant area.

8.11. Pollution Control Measure In Construction Phase

The overall impact of the pollution on the environment during construction phase is localised

in nature, reversible and is for a short period.

Air

The suspended particulate pollution generated during transportation will be mitigated by

covering the vehicles so as to ensure no spillage. Hosing down the wheels of the vehicles

with water and providing washing troughs for them would further mitigate the amount of dust

generated. In addition, emission of other pollutants from construction machinery using diesel

driven prime movers, will be controlled by proper maintenance.

Noise

Noise emissions from construction equipment will be kept to a minimum by regular

maintenance. Heavy and noisy construction work will be avoided during night time.

Water

Drinking and sanitation facilities at the complex will be provided to the construction

workforce. This is necessary to reduce pollution of any receiving water body and also to

prevent hazards due to water borne vectors. Potable water shall be provided to the workers.

B





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Socio Economic

R & R plan as approved by District Collector will be strictly adhered and compensation will

be provided. However, R&R is not applicable if no new land is acquired.

8.12. Pollution Control Measure In Operation Phase

It is envisaged that with strict adherence to the pollution prevention and control measures

during the design stage, the environmental impacts could be moderated to the minimum

possible level during the operation phase.

Air

In-plant Control Measures

Some of the important operational measures, which can reduce the impact on air

environment, are as follows:

- Gaseous fuel (maximum possible) will be used in heater & boiler to minimize air

emission.

- Use of low sulfur fuel for minimization of SO2 emission.

- Provision of low – NOX burners in heaters / furnaces / boilers to minimize NOX

emission.

- Provision of high efficiency furnaces (more than 90% efficiency) to minimize fuel

consumption.

- All the emission standards will be met for gaseous emissions.

- Continuous stack monitoring for ambient air pollution.

- Blow down (CBD) system for all the process units to minimize VOC emission from

the operations.

- Leak Detection and Repair (LDAR) programme for fugitive hydrocarbon emission

control will be followed.

- Ensuring preventive maintenance of equipment.

- Developing green belt in the proposed plant premises.

- Ensuring the operations of various process units as per specified operating

guidelines/operating manuals.

- Strict adherence to maintenance schedule for various machinery/equipment.

- Good housekeeping practices

Stack and Ambient Air Monitoring

In order to keep a check on the emissions of SO2, NOx, SPM and CO from

reactor/regenerator, boiler and furnace stacks shall be monitored as per statutory

regulations. Continuous monitors for emissions shall be installed on all major stacks.

Ambient Air Monitoring Stations shall continuously monitor quality of the air in the vicinity

of the plant complex. Laser based instruments for measuring Sulfur Dioxide, NOx,

Particulate matters, Ozone, Lead, Ammonia, Benzene, Benzo(a)Pyrene, Arsenic, Nickel,

Carbon Monoxide, Hydrocarbons shall be used in these Monitoring Stations.

Noise

As the plant is going to be operational on a 24-hour basis, noise considerations are very

important. All equipments will be specified to meet 85 dB (A) at 1 m distance. The





NRL

Document No.

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Page 14 of 15

exposure of employees working in the noisy area shall be monitored regularly to ensure

compliance with the OSHA requirements.

A green belt of appropriate width around the plant complex will be developed. Treated

Sewage will be used for irrigating this belt.

This green belt will help to reduce the noise and visual impact upon the surrounding

population as much as possible.

Water


Some of the measures, which can be taken up during operational phase of the complex

are:

- Reducing the actual process water consumption by way of improvement in operation

of processing units.

- Closed blow down system will be incorporated for hydrocarbon liquid discharges in

all the process units, which will reduce the wastewater load to ETP both in terms of

quantum load and quality. This is another of the in-plant control measures.

- Appropriate segregation and collection philosophy (separate sewers for process

waste, contaminated rainwater, spent caustic, cooling tower blow down, boiler blow

down etc.) will be incorporated for various effluents depending on individual stream

characteristics.

- A comprehensive wastewater management system to comply with treated effluent

quality as specified by CPCB shall be established.

- Process area will be paved to avoid contamination of soil/sub-soil/ground water in

case of accidental spill/leakage of hydrocarbon liquids.

- Looking into more options of reusing the treated effluent besides fire water make up

or for horticulture development.

- Ensuring proper monitoring and maintenance schedule for the effluent treatment

plant.

- Providing reuse and recycle of the treated effluent and water.

Water Quality Monitoring

The monitoring of raw influent, treated effluent and the ground water quality in the

surrounding areas will be carried out regularly. For regular monitoring of the operation of

various pollution control facilities, a laboratory with sophisticated instruments and well-

trained manpower shall be established. A separate Pollution Control Cell with qualified

Chemical Engineers/Scientists also form part of the facility, which will ensure that all

pollution control measures are effectively operating and to carry out day-to-day checks,

trouble shooting and further improvements wherever necessary.

Land

To improve the environmental quality following measures are recommended.


- The solid waste generated in the form of packaging material etc. shall be sold off for

making it suitable for reuse by reprocessing.





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Document No.

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Rev. No. B

Page 15 of 15

- The solids wastes identified to be sent to nearby authorized landfill agency for further

disposal.

- In order to improve the aesthetics in the plant surrounding, further plantation shall be

carried out the around the plant boundary.

Socio-Economic

Since the project is big in nature it will affect the socio-economic status of the region due to

high intensive investment, development of infrastructure such as road, railways

communication, education and other common facilities. There will be cascading effects on

economic status and avenues in the area as well as in the buffer zone where in there will be

growth in employment scenario. However there will be adverse impact in terms of usage of

common resources as well as rise in the price of commodities and environmental pollution

However, NRL shall take part actively in the overall development of the area.

8.13. Environment Cell

A Plant Safety & Environment Department under its technical services department, which

consists of well-qualified and experienced technical personnel from the relevant fields should

be in place to look after Environment cell. The Environment Cell will look after the

compliance of statutory Environmental standards applicable for the proposed project.


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 1 of 7

Project Implementation and Schedule for DFR



NRL

SECTION 9.0

PROJECT IMPLEMETATION AND SCHEDULE


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 2 of 7




NRL

9.0 PROJECT IMPLEMENTATION AND SCHEDULE

Project implementation and schedule for NRL PP can be referred in the following

attachments:

Attachment 9A: Stipulation of project schedule

Attachment 9B: Overall project schedule


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Rev. No. A

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NRL

Attachment 9A


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Rev. No. A

Page 4 of 7




NRL

General

The proposed Schedule has been prepared considering following facilities

Zero date has been considered as receipt of BDEP.

Environment clearance is considered under NRL scope and considered to be available

on start offsite enabling / grading activities.

All statutory approvals (CEA, PESO, AAI etc.) for establishment of new facilities have

been considered in scope of Client.

All As-Built Drawings and other inputs shall be provided to EIL by NRL on or before

Kickoff Meeting.

Thermal design of equipment is considered under Licensor scope of BDEP.

Site free from encumbrances shall be handed over at the start of pre-project activities.

ODC Route Survey report is considered to be made available on or before Zero date by

Client.

Existing Bullet at NREP plot is adequate to be used for Propylene Storage.

Utilities requirement such as Steam, DM water, Condensate, BFW, N2, IA / PA, Flare,

Treated raw water, etc., will be met from existing utility systems from NREP.

Fabrication / Lay down area for the following shall be arranged by Client (NRL):

- Structure steel storage, fabrication

- Piping shop fabrication

- Site fabricated equipment

- Office Space & Storage to the working agencies.

Following pre project activities / facilities has been considered by awarding a tender.

- Topographical survey

- Soil Investigation work

- Site enabling (Boundary Wall, Fencing, approach road, site Grading, Road, drain,

- culverts, Area Lighting, etc)

- Construction Power / Construction Water/ Temporary construction facility

- Site Office / Central Warehouse / Open Storage yard.

Project Implementation Stage (EPCM SERVICES / OBE – as applicable)

Following Units, Utilities & Offsite facilities has been considered for execution.

Major Process Units

POLY PROPYLENE UNIT (PPU) : 360 KTPA

Associated Facilities

Cooling Tower (2+1) with capacity 4000 Cum /Hr. each along with recirculation

Pumps and other accessories.

Offsite Storages / Buildings

Propylene Bullets (3 Nos.) (2 W+ 1S)

Polypropylene Warehouse

Polypropylene Laboratory

Canteen

Control Room

CRR and Sub Station

Fire Station

Service Building

B

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NRL

Dry Chemical Powder (DCP) Building

Chemical Storage Building

Philosophy of Execution: Poly Propylene Unit (PPU) & Associated Facilities

1. Project execution mode is EPCM / OBE as applicable. However following packages

considered as LSTK Contract :

Cooling Tower

Bullets

Extruder Pelletisation Package

Pneumatic Conveying Package

TEAL Package

2. Permanent power required for this unit considered to be sourced from existing refinery.

3. Total 4 Nos (1 UG + 3 AG) of Piping MTOs have been considered.

4. Tendering cycle time duration is considered as 3 and 4 months for item rate contracts

and package contracts respectively.

5. Ordering cycle of category-II equipment / materials is considered as 3 and 3.5 months

for indigenous and global MRs respectively and for Category – I equipment / material,

2.5 & 3 months for indigenous & global MRs respectively.

6. Based on Licensor BDEP, Vendor list will be finalized to be adopted for execution of

project.

7. Provision for air freighting of imported items shall be made depending on schedule

requirement.

8. Duration of Max. 2 weeks is considered for documents requiring Client’s comments /

approval. Efforts to be made to get the documents approved with-in a week or across

the table.

9. Since the expected zero date is not known, monsoon period is not indicated on the

schedule bar chart. However, the construction activities shall have the Monsoon period

impact (~3 Months/year from July to September). Adequate monsoon protection shall be

kept in scope of respective contractors.

10. Procurement of structural steel, cement, cable trays, cable ducts, lighting fixtures etc.,

have been considered under respective contractor scope.

11. Barricading works wherever deemed necessary is considered under respective

contractors.

12. The erection of heavy equipment considered in respective Package contractor /

Mechanical contractor scope.

13. Composite Works included to get more competitive bids. Composite works included in

Mechanical, piping, Painting, insulation.

14. Hook ups will be made part of Mechanical works tender.

15. Separate contract for Electrical & Instrumentation works is considered. Based on

requirement (if any), tender for Electrical and Instrumentation works can be merged with

composite works as stated in point no. 16 above, depending upon finalized Execution

methodology in due course.

16. Based on finalisation of Execution philosophy, to execute the Hookups required,

shutdown is envisaged for providing utilities to new Polypropylene Unit.


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Page 6 of 7




NRL

17. Covid – 19 protocol and SOPs shall be taken care by respective contractors and for

compliance.


Document No.

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Rev. No. A

Page 7 of 7




NRL

Attachment 9B

MONTHS ------------------->

-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

1 AWARD OF LOA

2 KICK OF MEETING Within two Weeks

3 CLIENT INPUTS

3.1 ENCUMBURANCE FREE LAND HANDING OVER

3.2 AVAILABILITY OF ODC ROUTE SURVEY

3.3 AVAILABILITY OF LICENSOR BDEP

3.4 STATUATORY APPROVALS (EIA / RRA) EIA RRA (AFTER CLIENT INTIMATION)

3.5 ASBUILT DRAWINGS AND OTHER INPUTS

4 SITE ENABLING ACTIVITIES AND PRE-PROJECT ACTIVITIES

4.1 TOPOGRAPHY SURVEY

4.2 SOIL INVESTIGATION SURVEY

4.3SITE ENABLING WORKS (BOUNDRY WALL / FENCING / APPROACH ROAD / SITE GRADING / ROADS / DRAINS, CULVERTS)

4.4 CONSTRUCTION POWER / WATER

4.5 SITE OFFICE / CENTRAL WAREHOUSE / OPEN STORAGE YARD

5 PROJECT IMPLIMENTATION STAGE (COMMON FOR BOTH SCHEDULES A & B)

5.1 RESIDUAL BASIC ENGINEERING

5.2 DETAILED ENGINEERING

6 PROCUREMENT

6.1 LLIs

6.1.1 POLYMERIZATION REACTOR AT SITE DURATION: 18-20 MONTHS

6.1.2 COMPRESSORS AT SITE

6.1.3 COLUMNS AT SITE

6.2 PACKAGES

6.2.1 EXTRUDER & PELLETIZATION PACKAGE AT SITE DURATION: 20-22 MONTHS

6.2.2 PNUMETIC CONVEYING PACKAGE AT SITE DURATION: 16-18 MONTHS

6.2.3 TEAL PACKAGE (TRI ETHYL ALUMINUM PACKAGE) AT SITE DURATION: 18-20 MONTHS

6.2.4 BALANCE PACKAGES AT SITE DURATION: 14-18 MONTHS

6.3 BALANCE EQUIPMENT AT SITE DURATION: 08-14 MONTHS

6.4 BULK PROCUREMENT

6.4.1 BULK - PIPING

6.4.2 BULK - ELECTRICAL / INSTRUMENTATION

6.4.3 DCS

7.1 CONSTRUCTION

7.1.1 PILING

7.1.2 CIVIL/ STRL/ UG PIPING

7.1.3

BUILDING WORKS (SS / SRR / WARE HOUSE / LAB / CANTEEN / CONTROL ROOM / FIRE STATION / SERVICE BUILDING / TEAL BUILDING / DCP BUILDING / CHEMICAL STORAGE BUILDING)

7.1.4 COMPOSITE WORKS (MECH / PIPING / INSULATION)

7.1.5 ELECTRICAL & INSTRUMENTATION WORKS

7.2 PACKAGES

7.2.1 PACKAGES

7.2.2 OTHER PACKAGES (HVAC / EOT / CLEAN AGENT SYSTEM / FIRE FIGHTING SYSTEM)

7.2.3 COOLING TOWER PACKAGE DURATION: 14 MONTHS

7.2.4 BULLETS (02 New + 01 Existing) (08 M Dia X 80 M Length) DURATION: 18 MONTHS

8 MECHANICAL COMPLETION

8.1 MECHANICAL COMPLETION

9 PRE-COMMISSIONING AND COMMISSIONING

9.1 PRE - COMMISSIONING AND COMMISSIONING

LEGEND: TENDER Mat Requisition AWARD/ LOI MATERIAL DELIVERY (PART) ACTIVITY MATERIAL DELIVERY (FULL) ACTIVITY

DATE REV

S. NO DESCRIPTION REMARKS

DURATION: 06 MONTHS

DURATION: 15 MONTHS

DURATION: 04-08 MONTHS


DURATION: 20 MONTHS

DURATION: 05 MONTHS

DURATION: 20 MONTHS

DURATION: 20 MONTHS

DURATION: 12 MONTHS


PROJECT : PPU AND ASSOCIATED FACILITIES

L1 SCHEDULEB394-000-27-44-SO001

LOCATION : NUMALIGARH, ASSAM

CLIENT: NRL PURPOSE

ISSUED FOR DFR

APVD

SK

CHKD/ REVWD

DURATION: 08 MONTHS

DURATION: 08 MONTHS

AM0



TSS

PREP

DURATION: 14-18 MONTHS + 06 M Site works

DOCUMENT NO.

T R

HAZOP REVIEW

COMMISSIONING

MECH. COMPLETION

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FEILD ENGG.30% MODELLING 60% MODELLING 90% MODELLINGMTO UG

1ST MTO INTERMEDIATE MTO FINAL MTO

<---------------MAJOR CIVIL/STRL. DRAWINGS------------>

OVERALL PLOT PLAN

EQUIPMENT LAYOUT

R R

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1 / 1


Document No.

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Rev. No. B

Page 1 of 10

Project Cost Estimate for DFR



NRL

SECTION 10.0

PROJECT COST ESTIMATE


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 2 of 10




NRL

10.0 PROJECT COST ESTIMATE

10.1. Introduction Numaligarh Refinery Limited (NRL), a subsidiary of M/s OIL India Limited is a public sector

undertaking under the Ministry of Petroleum and Natural Gas. The refinery located at

Golaghat District in Assam was commissioned in the year 2000 with a crude processing

capacity of 3 million tonnes per annum (MMTPA) to process indigenous crude of Assam.

The refinery primarily produces MS & HSD conforming to BS-VI specification.

NRL is installing a parallel new refinery of crude processing capacity of 6 MMTPA to

expand its capacity from present 3 MMTPA to 9 MMTPA. The project is integrated with a

new crude oil pipeline from Paradip (Odisha) to Numaligarh (Assam) and a product

pipeline from Numaligarh to Siliguri where NRL has its own Marketing Terminal for

distribution of product.

NRL has engaged EIL for the Licensor Evaluation & Detailed Feasibility Study Report for

Poly Propylene Unit (PP Unit) of Numaligarh Refinery Expansion Project at NRL, Assam.

The capacity of Poly Propylene Unit is 360 KTPA.

10.2. Scope

The Project envisaged following process unit and Utilities & Offsites:

Unit Description Capacity Execution

Mode

Poly Propylene Unit 360 KTPA EPCM


Water System

Cooling Tower 2W +1 S @

4000m3/hr each

Cooling water Recirculation

Pumps 3 pumps (2W +1S) of

4000 m3/hr capacity, 60m Head,

Casing- Cast Iron, Impeller-

Bronze.

EPCM

Offsites

Propylene Transfer Pumps

1W+1S, 115m3/hr, 643.5m head.

Propylene reprocessing pump

1 stand by,20m3/hr, 335m head

Propylene Bullets 2W+1S,

Estimated total wt : 3108MT

EPCM

Truck Loading Facilities 72 Nos. Fork lift EPCM

Emergency DG set 750 KW EPCM

B

B

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NRL

10.3. Reference Document

Preliminary Equipment List & technical specifications, Engineering inputs, System

capacities etc.

10.4. Project Cost

Capital cost estimate for the project for the proposed scope of work and Units on EPCM

(Engineering, Procurement and Construction Management) execution methodology works

out as under. This is including cost escalation during implementation Phase.

Zero Project start date as Oct 2021: Rs 4,515.00 Cr with Foreign Component of

1331.11 Cr

Zero Project start date as Oct 2022: Rs 4,735.31 Cr with Foreign Component of

1372.73 Cr

This Capital cost estimate shall be read along with Key assumptions and Exclusions listed

at Para 10.5 & 10.6.

10.5. Key Assumptions

The basic assumptions made for working out the capital cost estimate are as under:

Licensor selection has not yet been completed. Project cost may change

according to final selected Licensor.

Cost estimate is valid as of calendar Oct 2021 price basis.

Execution methodology is EPCM.

Exchange rates considered are 1 USD = Rs 74.13

Cost estimate is based on preliminary information provided by Licensors and

available with EIL

MTO has been prepared based on available preliminary data. No detailed

engineering has been done for estimation.

Utility/Offsites, Distribution P&ID’s & Unit ISBL distribution P&ID’s are not yet

finalized. Any changes in same will have impact on MTO.

Detailed Constructability study has not been done.

Package inputs/ costs are based on preliminary details available. Same is likely

to undergo change during detailed engineering depending on selection of vendor.

Buildings have been considered as per table included

Detailed Soil investigation, UG scanning & topography survey report are not

available. On account of this site development quantities are only indicative.

No provision has been kept for any revamp.

B

B

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NRL

10.6. Exclusions

Following costs have been excluded from the Project cost estimate:

Land for PP Unit & Offsites

Escalation beyond calendar Oct 2021

Township

Railway siding

Removal of unseen / unidentified underground obstructions

Any cost (for Feed, Fuel, Utilities, Catalyst & Chemicals, etc.) towards the

stabilization of the plant or off spec product production.

Cost towards statutory clearances

Captive Power Plant

COT

Pollution control System/ETP

Onshore Pipeline if any

Workshop & Equipment

Infrastructure Facilities other than Approach Road

2 Years Operating & Maintenance Spares

10.7. Estimation Methodology

Cost estimate is based on cost information available from EIL’s current in-house cost data

and Engineering inputs for cost estimation purpose. In-house cost data has been analyzed

and adopted for estimation after incorporating specific project conditions. Cost data has

been updated to prevailing price level using relevant economic indices.

These Cost estimates are subject to identified scope of work and engineering inputs /

technical information, the qualifications, assumptions and exclusions stated herein.

The accuracy of these estimates is targeted at +/-20% based on the methodology used

and the quality of the information available for cost estimation.

10.7.1. Process Unit (PPU & Product Warehouse)

The cost estimate for PP Unit has been prepared based on equipment list / technical

information received from the licensor / technology provider and good for costing

purpose information from Engineering. Equipment cost has been estimated based on

available in-house cost data adjusted to the required capacity and time escalation.

Cost estimates for supply of Bulk Materials i.e. Piping, Electrical and Instrumentation in

process units has been made as factor of equipment cost based on in-house practice

from similar units. Cost provision for mandatory/insurance spares has been made on

factor basis as per in-house norms and procedures.

B


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NRL

Cost provision for Site erection works, Civil / structural works, Insulation & Painting

works, Fireproofing / Chemical Cleaning has also been made on factor basis as per in-

house norms.

PP Warehouse is considered as PEB steel type warehouse of size 290m x 100m. The

estimate is based on available in house data adjusted to the required size and time

escalation. Battery operated forklifts 72 No’s are considered in the estimate for PP

Warehouse.

The cost estimates for Process units are based on their battery limit scope only.

10.7.2. Utilities & Offsites

The cost estimate has been worked out based on technical information for each system /

in-house engineering information with recent in-house cost data available for similar

facilities implemented in other projects. The following equipment/ package are included

in the estimates:

Cost provision for Bulk Materials i.e. Piping, Electrical, Instrumentation and DCS is

based on MTO from in-house Engineering.

Instrumentation bulk mainly consists of Ducts & cables only.

Cost provision for spares consisting of mandatory spares has been made on factor basis

as per in-house norms and procedures.

Civil & Structural facilities envisaged as part of U&O have been estimated on MTO basis

from in-house Engineering for following items only. The broad quantities considered are:

RCC M30- 4500 m3,

Reinforcement [Fe500D]- 800MT

Description Details

Recirculating

Cooling Water

System

Cooling Tower 2W +1 S @ 4000m3/hr each

Cooling water Recirculation Pumps 3 pumps (2W

+1S) of 4000 m3/hr capacity, 60m Head, Casing-

Cast Iron, Impeller- Bronze.

Offsites

Propylene Transfer Pumps 1W+1S, 115m3/hr,

643.5m head.

Propylene Reprocessing Pump, 1No., 20m3/hr,

335m head

Propylene Bullets 2W+1S, Estimated wt : 3108MT

DG Set (750 KW)

Fire Fighting

Equipments

Mobile Fire fighting equipment, FW System

Hydrant system, Fire Extinguishers, Hose Reels,

Long Range Monitor etc.

B

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NRL

Steel [E350 Grade]- 3200MT

Cost provision for Site erection works, Insulation & Painting works, Fireproofing has

been made as a factor based on in-house norms.

10.7.3. Indirect costs, exchange rates & Statutory taxes/duties

The cost estimate is based on following Exchange Rates, Indirect & taxes duties:

Exchange Rate 1 US$ = Rs. 74.13

Ocean Freight 5.0% of FOB cost of imported equipment

Port Handling 2.0% of FOB cost of imported equipment

Inland freight 5% of FOB cost of imported equipment and ex-works

cost of indigenously sourced equipment

Customs Duty incl. IGST

25.20% (Basis Rate @ 7.5% +10% Social welfare

Surcharge, IGST-15.66%) after taking input tax credit

@ 13% on IGST

GST 15.66% after taking input tax credit @ 13% on GST

Insurance 1% of total cost

10.7.4. Land

Provision for Land for approach road is considered in the estimates. It is based on

following details for the approach road:

Approach road Land area=60000 m2

Land cost =Rs. 32 Lacs/Bigha, (1 Bigha in Assam is 1338 sq. meters)

10.7.5. Site Development

Provision for Site Development (i.e. Site grading / Earth work, Crossings, Sleepers, Pipe

way bridge, Drainage, etc. ) has been kept based on estimated MTOs / quantities of

respective activities from Engineering. Detailed Soil investigation, UG scanning &

topography survey report are not available. On account of this site development

quantities are only indicative

10.7.6. Process Knowhow, Basic Engg. Start up Assistance, License Fee & Training

Provision for Know-how / License fee and Basic Engineering, mandatory services,

additional services & training has been kept based on in-house information / licensor

information for Poly Propylene Unit. GST @ 15.66% has also been included.

Final provision shall be updated based on Licensor Selection.

10.7.7. PMC/EPCM Fee

Provision for EPCM consultant fee is included in the estimates. B


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NRL

10.7.8. Catalyst & Chemicals

Provision for first fill & 6 months of catalysts has been made based on information from

in-house for similar plants & in-house cost data and information received from various

Licensor.

Final provision shall be updated based on Licensor Selection.

10.7.9. Captive Power Plant

No Captive Power Plant is envisaged under this project. The power requirement has

been considered from the grid.

10.7.10. Lab Equipment

A Provision has been considered on Lump-sum basis for Lab Equipments.

10.7.11. Piling

Cost provision for Piling has been kept considering 6000 nos. piles of 500mm, 15m

length & M30 grade.

10.7.12. Buildings

Cost for buildings as listed below is included in the estimates.

Building MTO

Sl.No Building Name Type Floors L (M) B (M)

1 PP-SRR Blast 1 40 30

2 PP-CWTP SRR Blast 1 40 30

3 PP-SS RCC Framed 2 84 30

4 PP-CWTP SS RCC Framed 2 60 30

5 PP Ware House Steel 1 290 100

6 Control Room Blast 1 60 40

7 Polymer Lab RCC Framed 2 60 25

8 Canteen RCC Framed 1 40 20

9 Fire Station RCC Framed 2 60 30

10 Service Building RCC Framed 2 50 40

11 Gate House RCC Framed 2 20 10

12 Ware House

(Chemical, Spare) RCC Framed 1 25 25

B


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NRL

Cost provision for PP Ware-house has been kept separately and it is based on

preliminary size envisaged (Total 29,000 m2 area considered). A conventional type PP

Warehouse has been considered

10.7.13. Infrastructure Facilities

No additional cost provision has been made related to any infrastructure development

outside the plant battery limit except of 24 m wide x 3.5 km long and 9 m wide x 50m

long approach. Internal roads within the complex have been considered under Site

Development.

10.7.14. Construction Site Facilities

Cost provision for Construction Site Facilities like Site Office, Cement Go Down,

Construction Water & Power etc. is considered on factor basis @ 1.0% of Plant &

Machinery Cost.

10.7.15. General Facilities

Lump sum cost provision (0.5% of P&M Cost) has been made for Office Equipment &

Furniture, Canteen & Welfare Equipment, Safety & Medical Equipment, Training Center

Equipment etc.

10.7.16. Township

There are existing facilities for township. No augmentation of has been considered in the

estimates.

10.7.17. Owner’s Construction Period Expenses

Lump sum cost provision (2.0% of Project cost excluding Working Capital Margin and

IDC) has been made for Owner’s construction period expenses which is primarily for

Project Management, Salaries & Wages, Environment Clearances, Feasibility Reports,

Fund Raising, Recruitment, Training Requirement, Legal Expenses, Office and Vehicles

Hire / Rentals / Maintenance, Stationary, Postage, Travel etc. during project construction

period.

10.7.18. Start up & Commissioning Expenses

Lump-sum cost provision (2.0% of P&M Cost) has been made as per in house norms for

various requirements during start-up and commissioning period such as Chemicals &

Consumables, Vendor Servicemen, Technician & Operators required (except as stated

in next Para).

Cost for Feed, Fuel, Utilities & Catalyst, etc. towards the commissioning /

stabilization of the plant has been excluded.

B


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NRL

10.7.19. Corporate Environment Responsibility (CER)

Cost provision towards Corporate Environment Responsibility has been included @

0.50% of Project Cost excluding Working Capital Margin & IDC.

10.7.20. Contingency

Provision for contingency is kept @ 7.50%.

10.7.21. Working Capital/ Margin

Provision for working capital/margin is based on following details:

Goods in process : 4 days of sales

Finished goods: 20 days of sales

Bills Receivable (Outstanding): 21 days of sales

Cash in hand: 15 days of salary

Trade Credits: 30 days of feedstock cost

Inventory level for Catalysts & Chemical: 7 days of cost

25% of Working Capital is capitalized and 75% of working capital is considered for short

term borrowing in financial analysis.

10.7.22. Interest During Construction

Interest during construction period required for the project has been made on the

following basis.

Construction Period: 36 months

Phasing: 1st Year 20%

2nd Year 45%

3rd Year 35%

Interest Rate (Long term/Short term): 12.00%/8.00%

Debt/ Equity ratio: 70:30

Foreign Debt: 100%

Expenditure Pattern: Concurrent

Loan Repayment Period: 5 Years


Document No.

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NRL

CAPITAL COST

PROJECT :

SL. D E S C R I P T I O N ALL COST IN RS. LAKHS JOB NO. B394

NO. Fc Ic TOTAL CLIENT NRL

LOCATION Numaligarh

1 LAND (APPROACH ROAD) 14 35 14 35

2 SITE DEVELOPMENT INCL. ROADS 69 48 69 48 TYPE OF ESTIMATE

3 PROCESS KNOWHOW, BASIC ENGG. START-UP ASSISTANCE & LICENSE FEE

166 06 166 06

4 EPCM FEE 266 56 266 56 EXECUTION METHODOLOGY

4.1 GST 47 98 47 98

SUB TOTAL (1-4) 166 06 398 37 564 43 ESTIMATE VALIDITY

5.1 PROCESS UNITS

- Poly Propylene Unit 360 KTPA 483 11 1123 59 1606 71

- PP Warehouse 135 13 135 13

1 US $ = 74.13

5.2 CATALYST & CHEMICALS Initial Fill+6 Months 101 40 34 26 135 66

SUB TOTAL (PROCESS UNITS) 584 51 1292 98 1877 49

5.3 UTILITY & OFFSITES 18 09 659 46 677 54

5.4 CAPTIVE POWER PLANT Excluded

5.5 LAB EQUIPMENT 43 17 35 32 78 49

5.6 ONSHORE PIPELINE Excluded

5.7 COT Excluded

5.8 PILING 500mm, 6000 Nos 15m

79 11 79 11

5.9 BUILDINGS 187 31 187 31

5.1 POLLUTION CONTROL SYSTEM/ ETP Excluded

TOTAL (PLANT & MACHINERY) (5) 645 77 2254 18 2899 95

6 INFRASTRUCTURE FACILITIES Approach Road 26 47 26 47

7 CONSTRUCTION SITE FACILITIES 29 00 29 00

8 GENERAL FACILITIES 14 50 14 50 PREPARED BY Jitender Kumar/ Divya/ Shrestha

9 TOWNSHIP Excluded

10 OWNER'S CONSTRUCTION PERIOD EXPENSES 79 37 79 37 REVIEWED BY Ashu Chopra/ S Baishnab

11 START UP & COMMISSIONING EXPENSES 29 00 29 00 58 00

12 CORPORATE ENVIRONMENT RESPONSIBILTY (CER) 19 84 19 84 APPROVED BY Vineet Aggarwal

SUB TOTAL ( 1 - 12) 840 82 2850 73 3691 56 S U M M A R Y

13 CONTINGENCY @7.50% 276 87 276 87

SUB TOTAL ( 1 - 13) 840 82 3127 60 3968 42

14 WORKING CAPITAL MARGIN 56 29 56 29 DOCUMENT NO.

SUB TOTAL ( 1 - 14) 840 82 3183 88 4024 71 REVISION NO.

15 INTEREST DURING CONSTRUCTION (IDC) 490 29 490 29 DATE :

16 TOTAL PROJECT COST … AS OF VALIDITY 1331 11 3183 88 4515 00 PAGE :

17 TOTAL PROJECT COST … AS OF VALIDITY + 1 YEAR 1372 73 3362 58 4735 31 FILE NAME

Format no. 5-6842-1000-F1 Rev.3/1.11.2020

DETAILED FEASIBILTY STUDTY REPORT FOR PPU OF NREP

PROJECT COST SUMMARY

CAPACITY

+/-20%

EPCM

EXCHANGE RATES

PROJECT MANAGER

Dr. Shobha Aggarwal

COST ENGINEERING DEPARTMENT

Oct-21

PROJECT :

UNIT: UTILITY & OFFSITESCOST ENGINEERING DEPARTMENT

SL. D E S C R I P T I O N JOB NO. B394

NO. CLIENT NRL

Fc Ic Sc TOTAL LOCATION Numaligarh CAPACITY

1 EQUIPMENTS/SYSTEMS/UNITS UNIT

1.1 Cooling Tower Package (2W+1S) x 4000 m3/hr 21 60 21 60 LICENSOR

1.2 Pumps 9 69 2 48 12 171.3 Fire Fighting Equipments 29 51 29 511.4 Emergency DG Set 750 KW 1 18 1 18

1.5 Propylene Bullets (8m x80m) (1036 MT each), 03 Nos

3108 MT 170 94 170 94

SUB-TOTAL (1)... 9 69 33 17 192 54 235 402 BULK MATERIALS

2.1 Piping 38 26 38 262.2 Electrical 5 82 77 77 83 592.3 Instrumentation 5 35 5 352.4 DCS/PLC 7 51 32 7 83 EXCHANGE RATES

SUB-TOTAL (2)… 5 82 128 90 32 135 04 1 US $ = 74.133 Spares 1 45 1 26 2 714 Catalyst & Chemicals

SUB-TOTAL (1 TO 4)... 16 96 163 32 192 86 373 145 ERECTION / SITE WORKS

5.1 Equipment 5 14 5 145.2 Piping 22 96 22 965.3 Electrical 30 09 30 095.4 Instrumentation 4 47 4 475.5 Insulation / Painting 13 14 13 145.6 Crane Hiring Charges

SUB-TOTAL (5)... 75 80 75 80

6 Civil & Structural Works (Incl. U/G and Fire Proofing)

104 67 104 67

6a Buildings6b Piling

SUB-TOTAL (1 TO 6)... 16 96 163 32 373 32 553 617 Escalation During Execution 27 4 58 8 69 13 54

SUB-TOTAL (1 TO 7)… 17 23 167 91 382 01 567 14

8 INDIRECTS PREPARED BY Jitender Kumar/Divya/ Shrestha

8.1 Ocean Freight 86 86

8.2 Port Handling 34 34 REVIEWED BY Ashu Chopra/ S Baishnab

8.3 Inland Freight 9 26 9 268.4 Insurance 6 71 6 71 APPROVED BY Vineet Aggarwal

S U M M A R YSUB-TOTAL (8)... 86 16 31 17 17

9 TAXES & DUTIES9.1 Customs Duty Excl. IGST 1 49 1 499.2 IGST Component 3 07 3 079.3 GST 28 85 59 82 88 67 DOCUMENT NO.

REVISION NO.SUB-TOTAL (9)... 33 41 59 82 93 23 DATE :

PAGE :

TOTAL COST ... 18 09 217 63 441 83 677 54 FILE NAME

Format no. 5-6842-1000-F2 Rev.2/31.05.2019

ESTIMATE VALIDITY

NOTES


Oct-21

Dr. Shobha Aggarwal

PLANT & MACHINERY (UTILITY & OFFSITES )

ALL COST IN RS. LAKHS

TYPE OF ESTIMATE

EXECUTION METHODOLOGY

PROJECT MANAGER

+/-20%

EPCM


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 1 of 6

Financial Analysis for DFR



NRL

SECTION 11.0

FINANCIAL ANALYSIS


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 2 of 6




NRL

11.0 FINANCIAL ANALYSIS

This section is excluded from the report as per the scope of the work.

Financial analysis has been carried out for calculating IRR / NPV of the Project.

11.1 Financial Parameters

1 Construction Period 36 Months

2 Project Life 15 years

3 Debt / Equity Ratio 70:30

4 Capital Phasing (Total Capital)

4.1 1st Year 20%

4.2 2nd Year 45%

4.3 3rd Year 35%

5 Capacity Build – up

5.1 1st year 80%

5.2 2nd year 90%

5.3 3rd year 100%

6 Corporate Tax Rate 25.168%

7 MAT Nil

8 Foreign Debt 100%

9 Loan Repayment Period 5 Years

10 Moratorium Period debt 1 Year

11 Interest Long Term debt 12%

12 Interest Short term debt 8%

13 Expenditure Pattern Equity Concurrent to debt

11.2 Capital Cost

Capital cost has been considered as detailed in Capex section.

11.3 Operating Cost

Operating cost consists of Variable Operating Cost & Fixed operating Cost.

Fixed Operating Cost:

It consist cost towards Salary & wages, Plant & admin overheads, repair & maintenance

and insurance.

Salary & Wages are based on manpower details & CTC as given below


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 3 of 6




NRL



Total 17 36

CTC per person, Lakhs per

annum

38.17 29.94

Cost towards Plant & admin overheads, repair & maintenance, insurance is based on

factor as given in Licensor methodology. The factors considered are as follows:

Plant & Admin Overheads : 0.50 % of Installed Cost

Repair & Maintenance : 2.50 % of Installed Cost

Insurance & taxes : 1.00 % of Installed Cost

Variable Operating Cost:

Annual variable operating cost has been considered towards raw material / feed, utilities

& catalyst chemicals.

Feed and utilities quantities are considered as differential of New case (NREP + PP)

Max Propylene and Base case (NREP) Min LPG. Refer Operating Cost Sheet for details.

11.4 Annual Sales Realization

Annual sales realization for has been worked out based on product prices and

differential quantities of New case (NREP + PP) Max Propylene products and Base case

(NREP) Min products. Refer Annual Sales Realization Sheet for details.

11.5 Working Capital Margin

Provision for working capital/margin is based on following details:

Goods in process (4 days of sales)

Finished goods (20 days of sales)

Bills Receivable (Outstanding) (21 days of sales)

Cash in hand (15 days of salary)

Trade Credits (30 days of feedstock cost)

Inventory level for Catalysts & Chemical (7 days of cost)

25% of Working Capital is capitalized and 75% of working capital is considered for short

term borrowing in financial analysis.

11.6 Financial Analysis

Financial analysis has been carried out based on discounted cash flow. The results of

financial analysis are as below.


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 4 of 6




NRL

Financial Results:

11.7 Sensitivity Analysis

Sensitivity analysis has been carried out to check the impact of variation of capital cost,

Opex and sales in IRR.

The results are tabulated as below

Sensitivity Analysis

Description Cost

Rs. Crore

Capital Cost with Financing

Charges 4515.00

Differential Variable Operating

Cost 320.98

Fixed Operating Cost 197.87

Total Operating Cost 518.85

Differential Sales Revenue 1624.68

IRR Results (Revamp Case) IRR Before Tax IRR After Tax

IRR on Total Capital 20.57% 18.24%

IRR on Equity 25.56% 21.52%

Description IRR Before Tax IRR After Tax

On Total Capital

Base Case 20.57% 18.24%

Capex +10% 18.80% 16.73%

Opex +10% 19.98% 17.75%

Sales +10% 23.34% 20.61%

On Equity

Base Case 25.56% 21.52%

Capex +10% 22.21% 18.66%

Opex +10% 24.44% 20.58%

Sales +10% 31.08% 26.19%

B

B


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 5 of 6




NRL

ANNUAL SALES REALIZATION OPERATING

COST WORKING CAPITAL

DOCUMENT NO. :

JOB NO. : B394

PROJECT : REV. NO. :

COST ENGINEERING DEPARTMENT CLIENT : NRL DATE :

PAGE :

SL.

NO. DESCRIPTION UNIT ANNUAL

QUANTITY FX IC FX IC TOTAL

A SALE OF PRODUCTS

Base case (NREP)Min LPG

1 LPG Tonnes 674000 38 662 2605 82 2605 82

2 POLY PROPYLENE Tonnes 0 87 041

3 BS VI GASOLINE Tonnes 1592000 43 188 6875 53 6875 53

4 BS VI HSD Tonnes 3256000 39 496 12859 90 12859 90

5 RUF BOTTOMS TO EX COKER Tonnes 555000 24 815 1377 23 1377 23

6 SULPHUR Tonnes 145000 47 44 68 79 68 79

TOTAL 23787 27

New case(NREP + PP)Max Propylene

1 LPG Tonnes 496000 38 662 1917 64 1917 64

2 POLY PROPYLENE Tonnes 346000 87 041 3011 62 3011 62

3 BS VI GASOLINE Tonnes 1518000 43 188 6555 94 6555 94

4 BS VI HSD Tonnes 3160000 39 496 12480 74 12480 74

5 RUF BOTTOMS TO EX COKER Tonnes 555000 24 815 1377 23 1377 23

6 SULPHUR Tonnes 145000 47 44 68 79 68 79

TOTAL 25411 95

DIFFERENTIAL SALES 1624 68

Format no. 5-6842-2000-F6 Rev.4 / 24.09.2015


ANNUAL SALES REALISATION

UNIT RATE (Rs.)

<---------- BASIS --------------> All Costs are in Rs. Lakhs

AMOUNT

DOCUMENT NO. :JOB NO. : B394

PROJECT : REV. NO. :


PAGE :

SL.

NO. DESCRIPTION UNITDIFFERENTIAL

ANNUAL

QUANTITY FX IC FX IC TOTAL

A VARIABLE OPERATING COST

1 FEED

1.1 ARAB LIGHT MT 31 872

1.2 ARAB HEAVY MT 29 902

1.3 NATURAL GAS MT 5 000 36 487 18 24 18 24

1.4 VR OF EXISTING REFINERY MT 29 735

1.5 COKER DISTILLATE MT 32 303

1.6 Naphtha MT 35 575

2 UTILITIES

2.2 Power KW-h 2080 00 000 6.50 135 20 135 20

2.3 Raw Water m3 20 00 000 17.00 3 40 3 40

3 ANNUAL CATALYST & CHEMICALS 164 14 164 14

TOTAL VARIABLE COST (A) 164 14 156 84 320 98

B FIXED OPERATING COST

1 SALARIES & WAGES 17 27 17 27

2 PLANT & ADMINISTRATIVE OVERHEADS 0.50% 22 57 22 57

3 REPAIR & MAINTENANCE 2.50% 112 87 112 87

4 INSURANCE 1.00% 45 15 45 15

TOTAL FIXED COST (B) 197 87 197 87

TOTAL OPERATING COST (A+B) 164 14 354 71 518 85

Format no. 5-6842-2000-F5 Rev.4 / 24.09.2015


UNIT RATE (Rs.)

<---------- BASIS -------------->

ANNUAL OPERATING COST AT 100% CAPACITY

All Costs are in Rs. Lakhs

AMOUNT

DOCUMENT NO. :

JOB NO. : B394

PROJECT :DETAILED FEASIBILTY STUDTY REPORT FOR PPU OF NREP

REV. NO. :


PAGE :

SL.

NO. DESCRIPTION DAYS QUANTITY (MT) UNIT TOTAL

REQUIREMENT RATE (Rs.) RS LAKHS

1 Goods in process 4 days of sales 19 50

2 Finished goods 20 days of sales 97 48

3 Bills Receivable (Outstanding) 21 days of sales 102 35

4 Cash in hand 15 days of salary 72

5 Trade Credits 30 days of feedstock cost

1 64

6 Inventory level for Catalysts & Chemical

7 days of catalyst cost

3 45

A NET WORKING CAPITAL 225 14

C MARGIN MONEY @25% 56 29

D BANK BORROWING @75% 168 86

Format no. 5-6842-1000-F4 Rev.4

WORKING CAPITAL MARGIN

All Costs are in Rs. Lakhs


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 6 of 6




NRL

FINANACIAL ANALYSIS

Rev. No.Sensitivity Factors Page No. _____ of ______Capital Cost 100%Sales 100%Operating 100%

S No.1 Construction Period in Years 3

2 Project Name3 Job No. B3944 Client Name NRL5 Project Life 156 Fixed Capital Cost Foreign Indeginous

Land 14 35Site Development 69 48Road/Drains/Culvert/BridgesEffluent Teatment plantPlant Building 322 44TownshipNon-Plant BuildingPlant & Machinery 645 77 2021 56Basic Engineering 166 06Detailed Engineering 314 54Start-up and Commissioning 29 00 29 00Owners' Management Expenses 79 37Working Capital Margin 56 29Contingency 276 87Total 840 82 3183 88Total Capital 4024 71

7 Short Term Bank Borrowing 168 868 Debt/ Equity Ratio 2.33 9 Expenditure Pattern

Equity Before Debt(B) CEquity Concurrent To Debt(C)

10 Foreign Debt As % of Total Debt 100%11 Loan Repayment period for Ind. Debt 5.012 Loan Repayment period for For. Debt 5.013 Moratorium Period (Indeginous Debt) 1.014 Moratorium Period (Foreign Debt) 1.015 Interest on Long Term Debt (Ind.) 12.00%16 Interest on Long Term Debt (For.) 12.00%17 Interest on Short Term Debt 8.00%18 Committment Charge - (Ind. Debt)

19 Committment Charge - (For. Debt)

201 Year 10.00% 10.00%2 Year 22.50% 22.50%3 Year 17.50% 17.50%4 Year5 Year

211 Year 10.00% 10.00%2 Year 22.50% 22.50%3 Year 17.50% 17.50%4 Year5 Year

221year 80%2year 90%3year 100%4year 100%

23 Annual Sales At 100% Capacity 1624 6824 Annual Fixed Cost 197 8725 Annual Variable Cost 320 9826 NPV @ (%) 12.00%27 Corporate Tax Rate 25.168%28 MAT (%)29 Section 80HH Applicable (Y/N) N30 Section 80 I Applicable (Y/N) N

Prepared by Reviwed by Approved by

Document No.

Capacity Build - up

Financial Input Parameters

Capital Phasing (Total Capital)

Capital Phasing (Foreign Capital)


Rev. No.Page No.

Job No. : B394Project : DETAILED FEASIBILTY STUDTY REPORT FOR PPU OF NREPClient : NRL All Costs are in Rs. Lakhs

Opening Balance Withdrawal Interest Commit.

ChargeClosing Balance Debt Opening

Balance Withdrawal Interest Commit. Charge

Closing Balance Debt Foreign Indigenous Total

6 40,247 12325 27921 838 28758 28758 838 838 41085

12 40,247 12843 28758 27921 2563 59242 30484 2563 2563 42810

18 90,556 28799 59242 62822 5439 127503 68261 5439 5439 95995

24 90,556 30027 127503 62822 9535 199860 72357 9535 9535 100091

30 70,432 25167 199860 48861 13457 262178 62319 13457 13457 83890

36 70,432 26289 262178 48861 17197 328236 66058 17197 17197 87629

42

48

54

60

Total 402,471 135450 279208 49029 328236 49029 49029 451500

Date Prepared by Reviwed by Approved by

Months Capital Cost EquityFINANCING CHARGES

_____ of ______

FINANCING CHARGES

Document No.

Total Invest

FOREIGN DEBT INDIGENOUS DEBT

Rev. No.Page No.

Job No. : B394Project : DETAILED FEASIBILTY STUDTY REPORT FOR PPU OF NREPClient : NRL All Costs are in Rs. Lakhs

FOREIGN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

CUMULATIVE DEBT 328236 328236 262589 196942 131295 65647

DEBT REPAYMENT 65647.27 65647 65647 65647 65647

INTEREST ON DEBT-FOREIGN 39388 37419 29541 21664 13786 5908

INDIGENOUS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

CUMULATIVE DEBT

DEBT REPAYMENT

INTEREST ON DEBT- IND.

TOTAL INTEREST ON DEBT 39388 37419 29541 21664 13786 5908

DEBT REPAYMENT (TOTAL) 65647 65647 65647 65647 65647


YEARS

YEARS

Document No.

_____ of ______

LONG TERM DEBT REPAYMENT

Job No. : B394Project : DETAILED FEASIBILTY STUDTY REPORT FOR PPU OF NREPClient : NRL

ASSET VALUE RATE ASSET VALUE SALVAGE VALUE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

LAND & SITE GRADING 11298

NON PLANT BUILDING 1.63%

PLANT BUILDING 3.34% 44023 1397 1397 1397 1397 1397 1397 1397 1397 1397 1397 1397 1397 1397 1397 1397 23070

PLANT & MACHINERY 5.28% 386581 19391 19391 19391 19391 19391 19391 19391 19391 19391 19391 19391 19391 19391 19391 19391 95718

WORKING CAPITAL 5628.509477 5629

TOTAL 447531 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 124416

ASSET VALUE RATE ASSET VALUE SALVAGE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 VALUE

LAND & SITE GRADING 11298 11298

EFFLUENT TREATMENT PLANT

NON PLANT BUILDING 10.00%

PLANT BUILDING 10.00% 44023 4402 3962 3566 3209 2888 2600 2340 2106 1895 1706 1535 1381 1243 1119 1007 9064

PLANT & MACHINERY 15.00% 386581 57987 49289 41896 35611 30270 25729 21870 18589 15801 13431 11416 9704 8248 7011 5959 33770

WORKING CAPITAL 5628.509477 5629

TOTAL 447531 62390 53251 45462 38821 33158 28329 24209 20695 17696 15136 12951 11085 9492 8130 6966 59760


DEPRECIATION

DEPRECIATION

__ of ___

Document No.

Rev. No.

DEPRECIATION ( WRITTEN DOWN VALUE METHOD )

Page No.

DEPRECIATION ( STRAIGHT LINE METHOD )

Rev. No.Page No.

Job No. :B394Project : DETAILED FEASIBILTY STUDTY REPORT FOR PPU OF NREPClient : NRLSL_NO. YEARS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A. Sales Revenue 129974.6 146221.4 162468.2 162468.2 162468.2 162468.2 162468.2 162468.2 162468.2 162468.2 162468.2 162468.2 162468.2 162468.2 162468.2Salvage Value 124416

B. Operating CostsAnnual Fixed Cost 19786.72 19786.72 19786.72 19786.72 19786.72 19786.72 19786.72 19786.72 19786.72 19786.72 19786.72 19786.72 19786.72 19786.72 19786.72Annual Variable Cost 25678.51 28888.33 32098.14 32098.14 32098.14 32098.14 32098.14 32098.14 32098.14 32098.14 32098.14 32098.14 32098.14 32098.14 32098.14

C. Intt. on S T Loan 1081 1216 1351 1351 1351 1351 1351 1351 1351 1351 1351 1351 1351 1351 1351D. Intt. on L T Loan 39388 37419 29541 21664 13786 5908E. Ammortization(Sec. 35D) 793.6848 793.6848 793.6848 793.6848 793.6848F. Business Profit 43247 58118 78898 86775 94653 103324 109233 109233 109233 109233 109233 109233 109233 109233 233649

Calculation of MATG. Dep. as per Comps. Act 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788H. Book Profit 22459 37330 58110 65987 73865 82536 88445 88445 88445 88445 88445 88445 88445 88445 212861I. MAT

Calculation of Normal I TDepreciation(WDV) 62390 53251 45462 38821 33158 28329 24209 20695 17696 15136 12951 11085 9492 8130 6966Gross Profit -19143 4867 33436 47955 61495 74996 85023 88538 91537 94096 96281 98147 99741 101103 226682Carry Forward Losses -19143 -14276Profit before Deductions -19143 -14276 19160 47955 61495 74996 85023 88538 91537 94096 96281 98147 99741 101103 226682Relief u/s 80hhRelief u/s 80IPost Deduction Profit -19143 -14276 19160 47955 61495 74996 85023 88538 91537 94096 96281 98147 99741 101103 226682

J. Normal Income Tax 4822 12069 15477 18875 21399 22283 23038 23682 24232 24702 25103 25445 57051

Calculation of MAT Credit

Excess of MAT over NITC F excess MAT over NITMAT Credit Adjustment

Tax to be Paid 4822 12069 15477 18875 21399 22283 23038 23682 24232 24702 25103 25445 57051

Date Prepared by Reviewed By Approved By

Document No.

_____ of ______

INCOME TAX CALCULATIONS

Rev. No.Page No.

Job No. : B394Project : DETAILED FEASIBILTY STUDTY REPORT FOR PPU OF NREPClient : NRL

CONSTRUCTION PERIOD OPERATING PERIOD1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

CASH INFLOW

A EQUITY 25168 58826 51456

B. DEBT 59242 140617 128377

C. OPERATING REVENUE 129975 146221 162468 162468 162468 162468 162468 162468 162468 162468 162468 162468 162468 162468 162468

D. SALVAGE VALUE 124416

CASH OUTFLOW

E. MAIN INVESTMENT 80494 181112 140865

F. FINANCING CHARGES 3401 14974 30654

TOTAL INVESTMENT 83895 196086 171519

G. OPERATING COST

H. ANNUAL FIXED COST 19787 19787 19787 19787 19787 19787 19787 19787 19787 19787 19787 19787 19787 19787 19787

I. ANNUAL VARIABLE COST 25679 28888 32098 32098 32098 32098 32098 32098 32098 32098 32098 32098 32098 32098 32098

J. INTT. ON SHORT TERM LOAN 1081 1216 1351 1351 1351 1351 1351 1351 1351 1351 1351 1351 1351 1351 1351

K. TOTAL COST 46546 49891 53236 53236 53236 53236 53236 53236 53236 53236 53236 53236 53236 53236 53236

L. GROSS MARGIN(C+D-H-I-J) 83429 96331 109233 109233 109233 109233 109233 109233 109233 109233 109233 109233 109233 109233 233649

M. DEPRICIATION (AS PER C.A.) 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788 20788

N. AMMORTIZATION (SEC. 35D) 794 794 794 794 794

O. NET MARGIN(L-M-N) 61847 74749 87651 87651 87651 88445 88445 88445 88445 88445 88445 88445 88445 88445 212861

P. INTT. ON LONG TERM DEBT 39388 37419 29541 21664 13786 5908

Q. PROFIT BEFORE TAX(O-P) 22459 37330 58110 65987 73865 82536 88445 88445 88445 88445 88445 88445 88445 88445 212861

R. TAX 4822 12069 15477 18875 21399 22283 23038 23682 24232 24702 25103 25445 57051

S. PROFIT AFTER TAX(Q-R) 22459 37330 53288 53918 58388 63662 67046 66162 65407 64763 64213 63743 63342 62999 155810

T. NET CASH FLOW 43247 58118 74075 74706 79176

U. LONG TERM DEBT REPAYMT 65647 65647 65647 65647 65647

ON TOTAL CAPITAL

BEFORE TAX -80494 -181112 -140865 83429 96331 109233 109233 109233 109233 109233 109233 109233 109233 109233 109233 109233 109233 233649

AFTER TAX -80494 -181112 -140865 83429 96331 104410 97163 93755 90358 87834 86949 86195 85550 85000 84531 84130 83787 176597

ON EQUITY

BEFORE TAX -25168 -58826 -51456 44040 -6736 14044 21922 29799 37677 109233 109233 109233 109233 109233 109233 109233 109233 233649

AFTER TAX -25168 -58826 -51456 44040 -6736 9222 9852 14322 18802 87834 86949 86195 85550 85000 84531 84130 83787 176597

83357.25825 96259.18 109161.1 109161.1 109161.1 109161.1 109161.1 109161.1 109161.1 109161.1 109161.1 109161.1 109161.1 109161.1 234056.583357.25825 96259.18 109161.1 109161.1 97424.62 89632.47 86625.11 85479.39 84611.23 83952.12 83450.61 83068.01 82775.24 82550.43 175838.8

S NO. DESCRIPTION

Document No.

_____ of ______

CASHFLOW STATEMENT

Rev. No.Page No.

Sensitivity Factors Capital Cost 100%Sales 100%Operating 100%

Job No. : B394Project :

Client : NRLAll Costs are in Rs. Lakhs

FOREIGN INDIGENOUS TOTAL . FIXED CAPITAL COST 840 82 3127 60 3968 42

. WORKING CAPITAL MARGIN 56 29 56 29 . FINANCING CHARGES 490 29 490 29TOTAL INVESTMENT 1331 11 3183 88 4515 00

INTERNAL RATE OF RETURN

ON TOTAL CAPITALBEFORE TAX 20.57%

AFTER TAX 18.24%

ON EQUITYBEFORE TAX 25.56%

AFTER TAX 21.52%

NET PRESENT VALUEDISCOUNT RATE 12%

ON TOTAL CAPITALBEFORE TAX 205485 Lakhs

AFTER TAX 135198 Lakhs

ON EQUITYBEFORE TAX 186888 Lakhs

AFTER TAX 116601 Lakhs

PAYBACK PERIOD

ON TOTAL CAPITALBEFORE TAX 4.5

AFTER TAX 4.5

ON EQUITYBEFORE TAX 5.9

AFTER TAX 6.3

BREAK EVEN POINT(%) 51.04%

RETURN ON INVESTMENT 20.80%

DEBT SERVICE COVERAGE RATIO 1.00

PROFITABILITY INDEX ( COST-BENEFIT RATIO)

ON TOTAL CAPITALBEFORE TAX 1.65

AFTER TAX 1.43

ANNUAL REVENUE 162468.22 Lakhs

ANNUAL FIXED OPERATING COST 19786.71707 Lakhs

ANNUAL VARIABLE OPERATING COST 32098.14174 Lakhs


CAPITAL INVESTMENT

Document No.

_____ of ______

FINANCIAL RESULTS



Document No.

B394-RP-79-41-0001

Rev. No. A

Page 1 of 3

HSE for DFR



NRL

SECTION 12.0

HEALTH, SAFETY AND ENVIRONMENT


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 2 of 3

HSE for DFR



NRL

12.0 HEALTH, SAFETY AND ENVIRONMENT

In order to ensure identification of any hazards associated with the project, which could

adversely affect the health and safety of personnel both within and outside the complex,

and the environment, a sound Health, Safety and Environment (HSE) policy is proposed

to be adopted during the course of project execution with primary objectives as under.

a) Provide clearly defined safety system goals for the design aspects of the project.

b) Ensure a safe working environment for all plant personnel.

c) Through intrinsic safety in design, eliminate the potential for occurrence of

hazardous scenarios that can result in injuries, environmental damage, business

interruptions or loss of assets.

d) Minimize the risk and consequences of an accident which cannot be eliminated by

intrinsic safety in design.

e) Maintain satisfactory means of escape and evacuation from any conceivable

incident.

f) Minimize the potential for pollution of the environment from accidental spills,

venting or flaring of hazardous materials.

In order to ensure the above, it is proposed to carry out the following HSE related studies

during the engineering stage:

- Hazard identification (HAZID) study

- Hazard and Operability Study (HAZOP)

- Quantitative Risk Assessment (QRA) Study

- Hazardous Area Classification

Other health hazards that are proposed to be studied are as follows:

a) Lighting

b) Noise

c) Thermal Environment

12.1 Environment

Wastes are streams that are not produced for sale or internal consumption. Some of

these wastes may be toxic, poisonous, flammable and harmful to the environment.

Hence, it is of utmost importance that the wastes generated are disposed off safely.

When waste production cannot be avoided, the following design principles shall be

adopted to achieve environmental compliance:

a) Minimise the waste generation

b) Safe disposal facilities within development boundary

c) Safe disposal facilities outside the unit.

Wastes generated are of three types:


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 3 of 3

HSE for DFR



NRL

a) Solid

b) Liquid

i. Aqueous

ii. Non-aqueous

c) Gaseous

i. Point source gaseous emissions

ii. Fugitive emissions

Adequate care will be taken in process design to minimize the quantity of waste

produced. In addition, solid, liquid and gaseous wastes generated from various

processes in the refinery will be handled in a manner that minimizes their impact on the

environment. Some of the measures to be taken are as follows:

Solid Waste - It is recommended to dispose off solid waste such as spent catalyst,

tank bottom sludge and ETP sludge in secured landfills outside the refinery complex.

Liquid waste - A fully fledged Effluent Treatment Plant (ETP) based on the state-of the

art technology has been considered in the refinery to treat various liquid effluents

generated in the refinery complex as well as PP complex

Gaseous Effluents - Atmospheric emissions related to the proposed facilities emanate

mainly from the stacks located in various process units and in the CPP.

SOx Control - In order to control SOx emissions according to NEMA guidelines,

it is proposed to use internal fuel oil with maximum sulphur of 0.5 wt%.

NOx Control - Low NOx burners have been recommended to reduce NOx

emission from all furnaces.

In addition a Plant Safety and Environment Cell consisting of qualified and

experienced technical personnel from the relevant fields will be in place to

ensure effective operation of all pollution control measures and suggest further

improvements where necessary.


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 1 of 2

Recommendations for DFR



NRL

SECTION 13.0

RECOMMENDATIONS


Document No.

B394-RP-79-41-0001

Rev. No. B

Page 2 of 2

Recommendations for DFR



NRL

13.0 RECOMMENDATIONS

Based on the analysis detailed out in the previous sections, the following is concluded:

The project having capital cost of Rs 4515 Crores (with accuracy of ±20% and valid as of

Oct 2021) can achieve viability with a return of 18.24% post tax based on the product

prices.

Setting of PP Project, for which NRL has land in possession as well as its good

connectivity to the existing refinery for feed and utilities, proximity to highways and ease of

getting environmental clearance, will meet the petrochemical demand of north eastern

region which is expected to grow in future.

Also Polypropylene complex will accelerate development of downstream petrochemicals

industry for polymer processing like packaging, fibre and filament, automotive, health care

and personal care.

The development of clusters of small and medium industrial units associated with

petrochemical industry will not only improve the general infrastructure by improvement of

roads, education and health facilities but also generate tremendous employment

opportunities. This project will thereby improve the economic status of the people in the

area surrounding the Refinery/ petrochemical hub.

The Economic analysis portrays a robust and attractive rate of return for refinery

configuration with PP, this is primarily due to the high value polymer product. Hence it is

recommended that since the PP project results in a significant return on investment, same

can be taken forward for implementation.

Considering the high IRR, the pre-project activities may be taken up on immediate basis

after having internal approval within NRL. This will give an opportunity to NRL to almost

match PP Project with the implementation of existing NREP project and realise the full

potential of PFCCU from day one, ensuring high profitability.

B


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 1 of 1

Annexure-1 for DFR



NRL

ANNEXURE-1

OVERALL PLOT PLAN

12.5M WIDE ROAD 12.5M WIDE ROAD

386.2

214.5

60.0

287.8

539.0

55.065.1

74.4

61.5

157.7

221.0

400.5

BOUNDARY WALL

BOUNDARY WALL

GREEN BELTBOUNDARY WALL

(2+1)

COOL

ING

TOWE

R

15

FLARE

15

41-TT-121A

E - 859.15

N -1092.50

RCC FIREWALL

EXISTING EARTHEN DYKE58.0

19.1

RCC DYKE WALL

INCINERATOR

NOTE 7

9.7

S

8400 SQM

55.0177.081.088.022.065.0

15.0

1.015.0

T

3300 SQM

RCC DYKE

Ht. = 0.6m63.0

9.0

21.0

71.0

9.0

8.0

17.015.510.5

8.0

9.0 9.0

18.019.0

RCC DYKE

Ht. = 0.6m

Ht. = 0.6m

PFCC FEED

Ø42.0 Ø26.0

DCU FEED8.5

21.0

RCC DYKE

8.0

RCC DYKE

Ht. = 0.6m

R10 R10R10

27.0

9.7

BM19

R10 R10

CATCHER

OIL

OIL CATCHER

NOTE 41

35.0

14.0

4.0

8.01.0

E 5

08

.0

00

E 5

96

.5

00

E 6

92

.0

00

1S72-TT-2805Ø45.0 1S72-TT-2803

1S72-TT-2002

RPTU FEED

WAREHOUSE - 1

ROAD NO-12

21.0

10.0

P5

WF-1

A

B

9M W

IDE R

OAD

9M W

IDE R

OAD

9M W

IDE R

OAD

9M W

IDE R

OAD

1347.7

SUMP

1

2

3

CWPS

PP UNIT

(29000 SQM)PP WARE HOUSE

(20X10 )GATE HOUSE

(25X25)

WARE HOUSE(CHEMICAL,SPARE)

(60X3

0)CW

TP SS

(40X3

0)CW

TP SR

R

ADMIN BUILDING

UNLOADING BAYLOADING/

FUTURE AREA

30.0

(60X3

0)PP

SS(40

X30)

PP SR

R

TRUCK PARKINGFIRE STATION

172.0

35.011.0

30.0 20.0 141.015.0 20.515.0 30.0

(40X60)CONTROL

ROOM

ENTRY

EXIT

12.5(20X10 )

GATE HOUSE

15.0

22.3

CANTEEN

POLYMER LABBAGGING

24.0

14.5

25.0

BLAST RESISTANT

16.0

23.0140.0

14.5

19.0

15.0 20.0 15.0 15.0

10.0

CONSTRUCTION FACILITY

25.0

40.0

15.0

N

KEY PLAN

THIS DRAWING

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.

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

REFERENCE DRAWING TITLEREF. DWG. NO.

PEM/PCAPPDCHKDREVISIONSDATEREV.

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

BY

NUMALIGARH REFINERY LIMITED

100.0

290.0

60.0

25.0

25.0

30.029.0

9.0

30.0

15.0

18.0

20.0

20.0

30.0

84.0

45.0

7.5

7.5

7.5

60.050.0

20.0

25.0

PARKING

(INCL.

OP. CA

BIN)

BLAST

RESIS

TANT

ENTRYEXIT

SATELLITE

12.5

PUMP HOUSE 30.0mX8.0m

8.0

22.0

17.0DG SHED

5.0

PROP

YLEN

EPR

OPYL

ENE

PROP

YLEN

E24

.0

16.0

74.0

CONST. FACILITIES

(15x15)

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N- 1200.00

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N- 1300.00

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N- 1400.00

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N- 1500.00

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N- 1600.00

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N- 1700.00

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N- 1800.00

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N- 1900.00

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N- 2000.00

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N- 2100.00

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E- 0.00

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E- 100.00

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E- 200.00

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E- 300.00

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E- 400.00

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E- 500.00

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E- 600.00

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E- 700.00

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E- 800.00

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E- 900.00

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E- 1000.00

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E- 1100.00

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E- 1200.00

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E- 1300.00

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E- 1400.00

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E- 1500.00

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E-5.00

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N-1277.00

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GREEN BELT

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WT-6

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WT-4

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30

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7.5

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E-(-)64.0

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N-1181.0

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N-1145.00

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WT-5

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N-1167.50

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E-(-)24.00

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N-1153.00

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TW-1

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E-(-)45.00

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N-1175.00

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FIRE TRAINING

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GROUND

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AMBIENT AIR

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STATION

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SHED

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RADIOGRAPHIC PIT ROOM

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30

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STORM WATER

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RESERVOIR

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P/H

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E-395.00

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N-1142.50

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PLC ROOM

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OIL CATCHER

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MONITORING

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N-1167.50

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N-1145.00

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PROPOSED PIPE RACK

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BOUNDARY WALL

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GREEN BELT (FOR PPU PROJECT)

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PROPOSED FACILITIES

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F

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HEATER

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FENCING

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F

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14.25°

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PLANT NORTH

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TRUE NORTH

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SW

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NW

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W

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S

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SE

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E

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NE

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N

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NW

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W

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SW

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S

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SE

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E

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NE

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N

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17:30 PM IST

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8:30 AM IST

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WIND ROSE

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4.5%

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6%

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26%

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15%

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6%

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10%

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11%

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15.5%

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9%

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(FROM)

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36%

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9%

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27%

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4.5%

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8%

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6%

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4%

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DERGAON

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NUMALIGARH

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BOKAKHAT

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KAMARGAON

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N

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H

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-

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37

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TOWNSHIP

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SITE

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REFINERY

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SITE

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HAUTELEY

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RLY. STN.

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ADHARSATRA

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R

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I

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V

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E

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R

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D

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H

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A

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N

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S

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I

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A

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R

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RIVER KALIANI

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RIVER DOIGURUNG

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NH-

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39

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NH-39

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TO DIMARPUR

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TO JAMUGURI

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TO MERAPANI

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TO DIMARPUR

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GOLAGHAT

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TO TITABAR

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TO JORHAT

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(50KM FROM

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NUMALIGARH SITE)

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TO GAUHATI

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(270KM FROM

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NUMALIGARH)

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RLY. STN.

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7KM

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10KM

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PHGIPATH

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PROPOSED BIO REFINERY

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SITE

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%%ULEGEND :-

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1:2000

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000

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17

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44

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00001

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C

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A

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ISSUED FOR COMMENTS

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04.08.21

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MDS

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(A Govt. of India Undertaking)

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16

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15

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14

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13

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12

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10

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9

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11

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8

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6

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7

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5

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4

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3

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2

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1

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A

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B

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C

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D

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E

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F

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G

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H

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I

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J

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K

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L

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M

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N

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O

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P

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16

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15

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14

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13

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12

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11

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10

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9

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8

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7

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6

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5

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4

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3

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2

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A

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B

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C

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D

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F

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G

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H

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K

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DFR PPU PROJECT

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%%UNOTES:

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OVERALL PLOT PLAN

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lEiw.Zk {ks= ;kstuk

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%%UAREA CHART:-

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2.PLANT AREA

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1.TOTAL AREA (2+3) (ONLY PPU PROJECT)

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B394-000-17-44-00001

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SJ

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SKN

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1. ALL DIMENSIONS AND COORDINATES ARE IN METERS.

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2. PIPE RACK AND PIPE SLEEPER SHOWN ARE INDICATIVE.

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3. ROAD WIDTH SHOWN IN THE DRAWING ARE INCLUSIVE OF BERMS/SHOULDERS ON

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BOTH SIDE OF ROAD.

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4. THE EL. 100.00 CORRESPONDS TO RL 21.05M ABOVE MSL.

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B394

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3.GREEN BELT AREA (>33%%%)

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232821 SQM

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348093 SQM

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115272 SQM

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5. DESIGN HIGH FLOOD LEVEL (H.F.L) OF THE AREA IS 4.73M.

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B

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CLIENT COMMENTS INCORPORATED & ISSUED FOR DFR

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16.08.21

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MDS

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SJ

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SKN

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C

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REVISED & REISSUED FOR DFR

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20.09.21

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MDS

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SJ

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SKN

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SERVICE

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PROPYLENE

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3

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NOS.

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80

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8

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LEN/HT. (M)

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DIA. (M)

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STORED CAP. EACH (MT)

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%%UPRESSURIZED STORAGE

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TAG NO.

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-

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MOUNDED BULLET

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1620

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REMARKS


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 1 of 1

Annexure-2 for DFR



NRL

ANNEXURE-2

SCHEMATIC FLOW DIAGRAM

"THIS DOCUMENT IS THE PROPERTY OF LUMMUS NOVOLEN TECHNOLOGY GMBH (LUMMUS). IT CONTAINS CONFIDENTIAL

INFORMATION OWNED OR CONTROLLED BY LUMMUS. THIS DOCUMENT MAY NOT BE PROVIDED TO ANY THIRD PARTY, NOR

MAY BE IT USED FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY PERMITTED IN YOUR COMPANY'S AGREEMENT

WITH LUMMUS. IN NO EVENT MAY IT BE USED FOR ANY WORK NOT PERFORMED ON THE LUMMUS LICENSED PROCESS OF

THAT AGREEMENT. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED ON

SUCH LUMMUS LICENSED PROCESS IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF LUMMUS."

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APPR.

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CLIENT

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REV.

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DATE

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ISSUE

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DESCRIPTION

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CHKD

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DWG

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ENG

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ORIG

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LPE

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PDM

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PE

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PM

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0

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JM

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BLOCK FLOW DIAGRAM

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MARCH 2021

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TECHNICAL PROPOSAL

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NUMALIGARH REFINERY LIMITED 360 KTA POLYPROPYLENE PLANT ASSAM, INDIA

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MG

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LUMMUS NOVOLEN TECHNOLOGY GmbH

C704

Rectangle


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 1 of 4

Annexure-3 for DFR



NRL

ANNEXURE-3

EQUIPMENT LIST


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 2 of 4

Annexure-3 for DFR



NRL

MAJOR EQUIPMENT LIST

Sl.no. Description

Treaters

1 Propylene Treater

2 Propylene Treater

3 Hydrogen Treater

4 Hydrogen Dryer

5 Propylene Treater

Vessels,Tanks,Drums

1 HP Nitrogen Buffer Vessel

2 Regeneration Recycle N2 KO Drum

3 Tea Holding Tank

4 Tea Vent Pot

5 Waste White Oil Tank

6 Silane Holding Tank

7 Additive Feed Hopper Vent Pot

8 Catalyst Preparation Vessel

9 Catalyst Metering Vessel

10 Catalyst Vent Pot

11 RG Compressor Suction Drum

12 Powder Collector

13 Flare K.O Drum

14 Degassing Vessel

15 Chase Gas Buffer Vessel

16 Phase Separator

17 Condensate Drum

18 Dry Flare K.O.Drum

Silo

1 Purge Silo

2 Pellet Blending Silos

3 Bagging Silo

Cyclone

1 RG Cyclone

2 Shutdown Cyclone

3 Carrier Gas Cyclone

Reactor

1 Polymerisation Reactor

Exchanger

1 Hydrogen Pre-heater

2 Hydrogen Cooler

3 Regeneration Recycle N2 Heater

4 Regeneration Recycle N2 Cooler 1


6 RG Condenser


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 3 of 4

Annexure-3 for DFR



NRL

Sl.no. Description

7 Carrier Gas Cooler

8 Extruder Off Gas Condenser

9 Vent Condenser

10 Hydrogen Preheater

11 Hydrogen Cooler

12 Regeneration Recycle N2 Heater



15 RG Condenser

16 Carrier Gas Cooler

17 Extruder Off Gas Condenser

Pump

1 Tea Metering Pump

2 White Oil Drum Pump

3 Isopropanol Drum Pump

4 Silane Metering Pump

5 Silane Drum Pump

6 Peroxide Metering Pump

7 Catalyst Suspension Metering Pump

8 White Oil Drum Pump

9 Recycle Pump

10 Condensate Pump

11 Waste Water Pump

Compressor/Blower

1 Regeneration Recycle N2 Blower

2 RG Compressor

3 Hydrogen Compressor

4 Nitrogen Compressor

5 Carrier Gas Compressor

Agitator

1 Waste Oil Oil Tank Agitator

2 Catalyst Preparation Vessel Agitaor

3 Catalyst Metering Vessel Agitaor


Document No.

B394-RP-79-41-0001

Rev. No. A

Page 4 of 4

Annexure-3 for DFR



NRL

Sl.no. Description

4 Polymerisation Reactor Agitator

Packages

1 Solid Additive Package

2 Bag Additive Discharge and Feeding System

3 Talcum/Silica Additive Discharge and Feeding

System

4 GMS Additive Discharge & Feeding system

5 Extrusion Package/ Extruder

6 Purge gas Recovery Unit

7 Extruder Vacuum Unit

8 Pellet Pneumatic Conveying System

9 Bagging Line

10 Peroxide Dosing skid

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