FEASIBILITY REPORT

FOR
NUMALIGARH REFINERY EXPANSION
PROJECT

NUMALIGARH REFINERY LIMITED ASSAM

EXECUTIVE SUMMARY
1. EXECUTIVE SUMMARY

1.1 Background

Numaligarh Refinery Limited (NRL), a subsidiary of Bharat Petroleum Corporation

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-IV/VI specification.

NRL intends to install 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 for the design of new refinery train will be high sulphur Arabmix
crude. MS & HSD produced from the new train shall meet the BS-VI specification.

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

With this intent NRL appointed EIL to prepare a Feasibility Study Report (FR) with
cost estimate of +/- 30% for the revised configuration for 6 MMTPA expansion for
Project

The executive summary documents the result of the study.

1.2 Objective & Basis of selected Configuration for feasibility study report

1.2.1 Objectives

The major objectives of the study for Refinery capacity expansion are:

 Maximization of HSD & MS production, MS and HSD from new train shall comply to
BS-VI grade requirements

 Complying to overall SOx emission limit for the refinery and meeting other pollution
control norms.
1.2.2 Basis

The basis of study in line with the objectives have been detailed out as follows:-

 Additional train capacity

6 MMTPA of crude.

 Crude Mix

Design Case: 30% Arab Light-70% Arab Heavy

 Following additional stream from existing refinery will also be fed to new expansion
refinery for product upgradation.

 Vacuum Residue from Existing Refinery:(306 KTPA)

 Coker Naphtha’s from existing refinery DCU. (45 KTPA)
 HCGO from existing refinery DCU. (109 KTPA)

 Crude assay : The crude assay followed are attached as attachment I and II in the
design basis.

 On stream factor : 8000 operating hours per year

 Limits on Product Demand : As provided by NRL and reported in Table No.

1 below:
Table 1: Product Demand

Present Product slate Desired Product

S No. Product (MTPA) (Existing Demand from new
Refinery) train (MTPA)
Liquefied Petroleum Gas
1. 57,000 As Produced
(LPG)
2. Export Naphtha 1,28,000 0
3. Petrochemical Naphtha 1,60,000 0
Domestic regular Motor 1,600,000 (Max)
4. 3,60,000
spirit, MS (BS-VI) (Note-1)
5. ATF 96,000 0
6. SKO/MTO 12,000 0
Domestic High Speed
7. 22,36,300 4,800,000 (Max)
Diesel, HSD (BS-VI)
8. Sulfur 4,500 As produced
9. Coke 80,000 As produced
 Crude Receipt Facility:

Crude Pipeline : Imported crude will be received through a cross country pipeline from
Paradip port .

Crude Storage: The new crude being high sulphur has dedicated storage within
refinery. Three tanks of 35,500 M3 will be located at Numaligarh refinery site. Balance
storage will be provided at Paradip port.

 Product dispatch facility

Product Pipeline: A new multiproduct pipeline to transport products from the refinery
is envisaged.

For white oils (MS/HSD/SKO/ATF): presently, the white oils are dispatched by both
road and rail loading facilities from existing dispatch facilities at Numaligarh and
Siliguri.

In addition to rail and road loading, one 16” cross country pipeline from Numaligarh to
Siliguri owned by Oil India Limited (OIL) is used for handling MS/HSD/SKO with 1.721
MMTPA capacity.

Additional Product dispatch facilities to be installed at Siliguri after utilising available

capacity at Numaligarh Marketing terminal and pipeline.
Adequacy of above existing product dispatch facilities to be checked for the combined
production of existing refinery and additional train. Addition/ augmentation for product
dispatch facility to be done in consultation with NRL.

 Products Storage: As the expansion refinery will be processing high sulphur crude
independent intermediate product storages have to be considered. However for final
product storage integration with existing facilities is to be considered for optimisation.

 Utilities: The utility system requirement for new train shall be independent of existing
refinery. Steam demand in the new refinery shall be met from new Utility Boilers. For
meeting the refinery steam requirements at different levels, new STG shall be
provided. The incidental power generated through new STGs shall be utilised for
power requirement of the complex. Balance power required shall be made available
from the grid for the new refinery operation.

 Raw Water: Additional water requirement will be available from river Dhansiri.

 Natural Gas: 2.3 MMSCMD of Natural gas will be made available for the new refinery
and the same is envisaged as fuel for utility boiler and process units, as required.

In case higher quantity of natural gas is required, the same shall be made available by
NRL.
1.3 Refinery Configuration

Further to the feasibility study carried out by EIL in Feb, 2015, NRL has identified the below
mentioned additional options for evaluation for which a configuration study has been carried
out by EIL.

 Residue Upgrading Facility (>90 % conversion)/ Full conversion HCU

 Residue Upgrading Facility (>90 % conversion) / PFCCU(LPG Maximization case) /
FCC Gasoline treatment Unit
 Residue Upgrading Facility (approx. 70 % conversion) with integrated VGO HDT/
PFCCU (LPG/Propylene Maximization Case) / FCC Gasoline treatment Unit.
 Residue Upgrading Facility (approx. 70 % conversion) with integrated VGO HDT /
PFCCU
(Diesel/Gasoline Maximization Case) / FCC Gasoline treatment Unit

From the outcome of configuration study result, NRL selected the configuration of
“Residue Upgrading Facility (approx. 70 % conversion) with integrated VGO HDT-PFCCU
(LPG/Propylene Maximization Case) / FCC Gasoline treatment Unit)” with the objective to
produce petrochemicals in future, with the use of robust technology.
As part of expansion project, MS, HSD & LPG shall be the main products from the new
refinery NRL may go for petrochemical production (Polypropylene). Also the PFCC unit
shall be capable of producing high yield of propylene in future.

The selected configuration Comprises of:

 Primary processing

- 6.0 MMTPA of crude to CDU/VDU

 Light ends Processing

- Naphtha Hydro-treater/Naphtha Iso-merisation/ Naphtha Continuous

Catalytic Regeneration Units (NHT/ISOM/CCR)

 Treating Facilities

- Diesel Hydrotreating Unit (DHDT)

- FCC Gasoline Desulfurization Unit

 Secondary Processing

- Petrochemical Fluidized Catalytic Cracker (PFCC, including cracked LPG

treating facility)
  Residue Upgradation

- Residue Upgradation Facility (RUF) comprising of Ebullated bed Resid

hydrocracker with integrated VGO Hydrotreater

 Auxiliary Units

- Hydrogen Generation Unit (HGU)

- SRU/SWS/ARU/TGTU

- Straight run LPG treating Unit (Comprising RUF and Straight run LPG treating
Unit)

 New Utilities and Offsite facilities

- New Utility Boilers to meet new refinery steam demand.

- Incidental power from new STGs and balance power required from grid.

- Intermediate & final product storage & handling facilities, as required.

1.4 Salient Features of configuration

1.4.1 Unit Capacities

The unit capacities for the new train for the design crude mix are summarised in table
1.2 below.

Table 1.2 Unit Capacities

Proposed Capacity
Process Units
(MMTPA)
Crude& Vacuum Distillation Unit (CDU/VDU) 6.0
Naphtha Hydro-treater 1.2
Reformer Unit 0.75
Isomerisation Unit 0.49
PFCC Unit 1.95
FCC Gasoline Hydro-Treater 0.58
Diesel Hydro-treater 3.55
Hydrogen Plant 95 (KTPA)
Residue Up-gradation Facility (Ebulated Bed 2.0
Resid Hydrocracker)
Sulphur Recovery Unit (SRU) 2 x 230 (MT/Day)

As integration with existing units has not been considered, none of the existing units
required revamp except coker unit. Existing Coker unit shall need to be revamped from 0.3
to about 0.55 MMTPA with feed integration with RUF bottoms of new refinery. The revamp
of Coker unit is not the part of this expansion project.
1.4.2 Product Slate

The estimated product slate of the expansion project for the design crude mix is
summarised in table 1.3 below. The graphical representation for both the case are also
given below in fig 1.1
Table 1.3 Product Slate

Propylene
LPG Minimization Case Maximization Case
Feed Purchase
(MMTPA) (Future Case) (Note-2)
(MMTPA)
Arab Light 1.8 1.8
Arab Heavy 4.2 4.2
Natural Gas 0.494 0.477
VR of existing refinery VDU 0.306 0.306
Coker Light and Heavy
Naphtha from existing 0.045 0.045
refinery DCU
HCGO from existing
0.109 0.109
refinery DCU
Product Sales (MMTPA)

LPG 0.500 (Note-1) 0.624

Propylene 0 0.330
BS VI Gasoline 1.572 1.301
Light Distillate 2.072 (29.8%) 2.155 (32.5%)
BS-VI HSD 3.370 3.180
Middle Distillate 3.370 (48.5%) 3.18(45.8%)
RUF bottoms to existing
0.561 0.544
Coker
Heavy distillate 0.561(8.1%) 0.544 (7.8%)

Sulfur (TPD) 434 434

Fuel and Loss 0.805 (11.6%) 0.812 (11.7%)

Note-1: LPG demand from Expansion Refinery to be limited to 500 KTPA. Excess of LPG
Produced, if any, to be used as feed to new HGU.

Note-2: The refinery may operate with high propylene yield in future to produce
polypropylene.
 LPG MIN CASE PRODUCT YIELDS (%)

• Light Distillate • Middle Distillate • Heavy distillate Sulfur • Fueland Loss

Figure 1.1: Graphical Representation for Product Yields for LPG Minimization Case

PROPYLENE MAXIMIZATION CASE PRODUCT

YIELDS(%)

• Light Distillate • Middle Distillate • Heavy distillate Sulfur • Fueland Loss

Figure 1.2: Graphical representation for product yields for Propylene maximization
Case (Future Case)
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1.4.3 Utility System Capacities

The estimated capacities and configuration of the utility facilities required to be installed for
the additional train are summarized in table 1.4 below

Table 1.4. Utility System Capacities

Sr
Utility System Capacity
No.

Required Capacity :- 1820 M3/Hr (Note-1)

 2 nos. of treatment plant of 1115 M3/Hr

of capacity each.

 Raw water reservoirs of 72,000 M3

1 Raw water System
capacity for one day water storage for
existing and new refinery.

 2 nos. of treated raw water reservoirs of

16,800 M3 capacity each for two days
water storage.

Design Capacity: - 44550 M3/Hr of recirculating

Cooling water.
CW system for process  11W+3S CT cells of capacity 4,000
2
units M3/Hr each

 6W+2S CW re circulating pumps of

8000 M3/Hr each.

Requirement :-11800 M3/Day of DM Water

3 DM Water System
 3W+1S RO-DM chains of 200 M3/Hr
chain capacity.

 2W + 1S UB producing 275 TPH of VHP

steam (each).
Steam, power & BFW
5
System  One extraction type 22 MW STG

 One extraction type 13MW STG

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 Sr
Utility System Capacity
No.

 96 MW grid power import

Design Capacity :- 85 M3/Hr of suspect

condensate
6 Condensate System
 1W+1S CPU chains of 85 M3/Hr chain
capacity.

Requirement: - 7780 Nm3/Hr of Instrument Air

& 2200 Nm3/hr of Plant Air.
7 Compressed air System
 3W+1S LP air compressor of 10,000
Nm3/ hr capacity each (Common for
nitrogen and compressed air system)

 1 cryogenic plant generating 1500

Inert Gas system Nm3/Hr of Gaseous Nitrogen and 225
8
(Cryogenic system) Nm3/Hr (equivalent, concurrent) liquid
nitrogen capacity.

72” Main flare stack

9 Flare System
24” Sour flare stack

10 Fuel Gas System 278 MMKcal/Hr of fuel fired

Note-1 : Raw water intake requirement finalized based on water balance across total
refinery complex(3 MMTPA + 6 MMTPA). For details of water balance, refer ‘Environment
Impact Assessment’ report for the expansion project.

1.4.4 Offsite Facilities

1. Philosophy for storage of crude: 21 days storage for crude is considered. Three
tanks of 40500 m3 nominal capacity to be installed at refinery. Balance 8 Nos. storage
tanks are considered at Dhamra port.

2. Philosophy for storage of final products: For finished products, total production
from existing 3 MMTPA Refinery as well as from upcoming new 6 MMTPA refinery has
been considered. Excess capacity in existing product tankages as well as Re allocation
of existing tanks service (for e.g. MS to HSD, etc.) in consultation with NRL have also
been considered for the expansion refinery. 10 days storage for all finished products

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 have been considered except for MS (BS-VI) storage, for which 8 days storage have
been considered as per NRL. Hence, no new finished product tanks have been
considered. LPG shall be stored in mounded bullets with around 8 days of storage
capacity.

3. Philosophy for storage of intermediate products: 8 days storage for VGO & VR is
considered. Bottoms of RUF unit is stored in existing tanks No. 45-TT-CR-107A/B,41-
TT-CR-108 A/B and one new storage tank shall be provided catering to total 8.5 days
of storage. All other intermediate products storage is considered for 3 days.

The details of offsite storage facilities required to be installed for the new refinery for
crude, products and intermediate products are summarized in table 1.5 below.

Table 1.5 Offsite Storage Facilities

Sr Numbers Nominal Capacity

Service
No. Required (M3)

Crude storage Tank at Refinery

1 3 40,000
(Note-3)

2 RUF Feed Tank 1 17,910

3 HCGO Tanks(for RUF feed) 2 4150

4 DCU Feed Tanks 2 7770

5 NHT feed tanks 2 8125

6 Straight Run VGO Storage Tanks 2 24500

7 PFCC Feed Tanks 2 19840

8 DHT feed storage 2 22240

6 (Mounded
9 LPG Storage Bullets) 90 (L) X8 (D)
(Note-1)

10 Light Slop 2 5000

11 Heavy Slop 2 5000

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 Notes:

1. Total 8 Numbers of mounded bullets to be provided. Initially 6 nos. of mounded LPG

bullets are required and later when the refinery shall operate with high propylene yield,
additional 2 nos of LPG bullets will need to be installed. In future, Propylene storage
bullets are also required.
2. Suitable pumping and blending system corresponding to feed, product and intermediate
product system also have been considered.
3. 8 Nos of new crude storage tanks have been considered at Paradip port.

1.4.5 Crude Receipt Facilities

Crude will be transported from Paradip port through new pipeline to new refinery train. 8
Nos of new crude storage will need to be considered at Paradip port as part of Crude Oil
Terminal.

1.4.6 Product Dispatch Facilities

Additional product dispatch facilities, required, both at Numaligarh and Siliguri are
summarized in Table 1.6 below

Table 1.6 Product Dispatch Facilities

Sr Products to be
Facilities Required Location
No. dispatched

Additional two numbers of

2 LPG road loading gantries (16 Numaligarh
bays) to be installed

4 Sulphur New truck loading facilities Numaligarh

Parts of White Oils (MS/SKO/HSD) are transported from Numaligarh to Siliguri by the
multiproduct Numaligarh Siliguri pipeline operated by Oil India Limited. The same is not
covered under this feasibility report. However cost of the pipeline has been provided by
NRL for the purpose of cost estimate.
1.4.7 Effluent Treatment Plant

A new effluent treatment plant with a capacity of 300 M3/Hr will be installed to treat the
effluent generated from the new refinery train. This effluent treatment plant will also
incorporate facilities for reclaiming water from the effluent for reuse in the refinery.

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