Pre-Feasibility Report

Proposed Debottlenecking of Existing Petrochemical

Complex along with Expansion of 48 MW Captive Co-
generation Power Plant (CCPP) to 240 MW CCPP based
on Coal / Pet coke

Prepared for

RELIANCE INDUSTRIES LIMITED,

PATALGANGA MANUFACTURING DIVISION (PMD),

PATALGANGA, MAHARASHTRA

May 2015

Reliance Industries Limited Page 1

 Contents

Section - 1: Executive Summary

Section - 2: Project Description
Section - 3: Plant Infrastructure & Basic Requirements
Section - 4: Environmental Aspects
Section - 5: Project Implementation
Section - 6: Project Approval and Clearances
Section - 7: Project Cost Estimate

List of Annexures

Annexure – 1: Topo sheet showing project location

Annexure – 2: Technical parameters of the CCPP
Annexure – 3: MIDC Industrial Area Notification
Annexure – 4: Overall plot plan

Reliance Industries Limited Page 2

 SECTION – 1

Executive Summary

Patalganga Manufacturing Division (PMD) of Reliance industries Limited (RIL) is located at

Patalganga MIDC, Village Mohopada, Tehsil Khalapur, District Raigad, Maharashtra. It is a
multi-product complex manufacturing a wide range petrochemical products, such as linear
alkyl benzene (LAB), Purified Terephthalic Acid (PTA), Polyester Fiber Yarn and Polyester
Staple Fiber, Polyester Industrial Yarn, Fully Drawn Yarn. It is envisaged to increase the
production of PTA from 25000 MT per month to 27500 MT per month as well as LAB from
8340 MT per month to 11000 MT per month by debottlenecking the processes. The power
and steam requirements for the process plants at PMD is met by 48 MW gas based Captive
Co-generation Power Plant (CCPP). Due to unavailability of gas and increase in demand of
power for facilities at PMD & other Reliance facilities, it is now proposed to expand the 48
MW CCPP to 240MW by addition of 174 MW (3 x50 MW + 1 x 24 MW) CCPP based on
Coal/Pet coke, and Efficiency Improvement Initiatives for Gas Turbines to increase power
output to 33 MW from each Gas Turbines. The raw material for the PTA & LAB plant shall be
heavy Naphtha / Reformate sourced either from BPCL/HPCL refineries at Chembur, Mumbai
or from Jamnagar Manufacturing Division (JMD) of RIL. The fuel to be used for the proposed
CCPP will be Coal / Petcoke which will be made available either through indigenous sources
or will be imported.

The proposed debottlenecking at PTA plant is a process envisaged for energy/material

recovery, energy conservation, and efficient energy utilization schemes. Similarly, the
debottlenecking at LAB plant is for replacing hazardous chemicals, converting low value by-
product and efficient energy utilization. Hence both these proposals will not result in any
increase in the liquid or gaseous emissions from PMD.

The proposed coal /petcoke power plant CCPP configuration shall comprise of Four units of
250 TPH high pressure CFBC boilers together with 3 units of 50 MW Steam Turbine
generators (STG) and one unit of 24 MW STG. The CFBC boilers will have inherent capacity
to handle wide range of solid fuel. Power generated, from the Co gen-CPP, is evacuated
through HT cables on the pipe rack. Also the system will be connected through suitable step
up transformer to the existing 100KV system or 220KV system as per the grid requirement.
The detailed description of the project is given in Section-2 of this report. Exisiting Gas
Turbines are site rated to 24 MW Capacity based on the derating of gas turbines to Local
Ambient conditions and aging / fouling of compressors, by replacing some of the parts of the
Gas Turbines and changing the control system software it is possible to increase the capacity
of the Gas turbines from 24 MW each to 33 MW each

The existing infrastructure facility at PMD shall be utilized for this proposed debottlenecking
as well as expansion of Co-Gen CPP. The CCPP expansion project shall be set-up in an
area within PMD. The power generating equipment considered for the station comprises of 4
nos. natural circulation CFBC boilers, 3 nos. non-reheat type steam turbine generator and
one extraction cum condensing turbine (existing) set using steam parameters within sub-
critical range, water cooled condenser, condensate extraction and boiler feed system along
with feed heating equipment like HP heater, steam condenser and deaerator. The steam
Reliance Industries Limited Page 3
generators would be semi-outdoor, balanced draft, natural circulating type having maximum
continuous evaporation at 110 bar, 515oC. The Turbine Generator set would be designed for
3 x 50 MW and 1 x 24 MW STG maximum continuous rating with water cooled condenser
having vacuum of 0.1 bar. The unit would be standard 3000 rpm, condensing, and single
cylinder machine with multiple extractions for regenerative heating. Auxiliary systems for the
power station like coal/pet coke and ash handling plants, plant water, compressed air,
ventilation and air conditioning systems together with miscellaneous auxiliaries and
ancillaries have been described in Section-3 of this report. The proposed power station will
be provided with the state-of-the-art Distributed Digital Control System (DCS), which will
integrate various closed loop sub-systems, open loop sub-systems, monitoring and
information sub-system covering the entire plant. The system will integrate the various
proprietary control packages supplied by the main equipment suppliers for harmonious plant
operation. The plant layout for the proposed plant has been developed taking into
consideration the optimum use of available land. Technical features of major plant and
equipment and plant layout are furnished in Section-3 of this report.

The debottlenecking proposal shall not add any additional environmental pollution in the
region. The proposed expansion of the CCPP will be equipped with state-of-the-art pollution
control devices to bring down the emission of pollutants to a level well within acceptable
norms of the country. The proposed CCPP will have the CFBC technology which uses lime
injection for reduction of SO2 emissions. This CFBC technology will also result is low NOX
emission and the adequate control mechanisms are in place to control the PM emission
which will be kept within statutory limits at all time. A general discussion on Environmental
aspect has been provided in Section - 4 of this report.

The proposed expansion is expected to be commissioned in 30 months from the date of

ordering of major plant and equipment. Proposed project implementation schedule has been
discussed in Section-5 of the Report. Section-6 deals with the various project approval and
clearances required from various government bodies. The estimated total project cost is
given in Section-7

Reliance Industries Limited Page 4

 SECTION – 2

PROJECT DESCRIPTION

2.1 INTRODUCTION
RIL intends to debottleneck the existing plant and infrastructure as well as install
CCPP at PMD. The debottlenecking of the existing plant which shall be at the Purified
Terephthalic Acid (PTA) plant and the Linear Alkyl Benzene (LAB) Plant, and this
proposal will not lead any increase in pollution. Along with this proposal of
debottlenecking, it is also planned to expand the CCPP. The CCPP which will supply
high pressure steam to the process and also augment the power generation capability.
Gas Turbines with HRSG and Auxiliary boilers are existing which uses natural gas and
HSD, Naphtha as fuel. Considering the less availability and higher costs of these
fuels, it is proposed to use Coal / Pet coke as fuel in the proposed CCPP.

2.2 Project Setting

The proposed project will be located within the existing complex at PMD at Mohapada
Village, Kalapur Tehsil, Raigad District, Maharashtra. PMD is located within MIDC
notified Industrial area and is well connected by rail and road network. Nearest railway
station Apta which is around 3 km. west of the site and Mumbai-Pune National
Highway (NH-4) is around 2.5 km. North-East of the site. Patalganga river flows about
500 meters north of the site. The proposed project location site is well connected by
rail and road and the site is at a distance of around 90 km. from Mumbai.

Overall climate is equable with average rainfall of 3000 mm per year and very few
days of extreme temperatures. The mean annual temperature ranges from 30 oC to
33oC. The mean maximum temperature of the hottest month in this area varies from
30oC-40oC in April-May while mean minimum temperature of coldest month varies
from 10oC to 20oC. Extremes of temperatures, like 44oC-45oC in summer and 10oC -
14oC in winter, may be experienced for a day or two in respective season. The area
has humid climate. Relative humidity varies from 25% to 85%. Driest days being in
winter and wettest ones are experienced in July. The rainy season is mostly confined
to southwest monsoon and is the source of fresh water supply. PMD location is as
given below; the topo sheet showing the project location is attached as Annexure 1

Reliance Industries Limited Page 5

 Location of Proposed Project Site

2.3. Debottlenecking Proposal

PTA Debottlenecking: The following modifications are being proposed which will
increase the PTA production from 25000 MT per month to 27500 MT per month.
 Installation of more energy efficient process air compressor train to use all surplus
steam generated.
 Improving process heat recovery from oxidation reactor overhead system.
 Installation of azeotropic distillation column.
 Installation of additional high pressure crystallizer.
 Installation of catalyst recovery unit.
 Replacing conventional two stage product separation with single stage rotary pressure
filter.

LAB Debottlenecking: The following modifications are being proposed which will
increase the LAB production from 8340 MT per month to 11000 MT per month.
 Replacing hazardous HF catalyst-based process with ionic liquid catalyst-based
process developed in-house.

Reliance Industries Limited Page 6

  Replacing existing mixer-settler based reactor with new reactor system.
 Installing Transalkylation process to convert low value by-product to LAB.
 This will also lead to increase in by-products quantity from 51598 MT per month to
75000 MT per month.

The above mentioned proposed debottlenecking at PTA plant is a process

envisaged for energy/material recovery, energy conservation, and efficient energy
utilization schemes. Similarly, the debottlenecking at LAB plant is for replacing
hazardous chemicals, converting low value by-product and efficient energy
utilization, both these proposals will not result in any increase in the liquid or
gaseous emissions from PMD.

The product slate at PMD along with the proposed debottlenecking is given below;

Post
Existing
Debottlenecking
Product Capacity
Capacity
(MT / M)
(MT /M)
LINEAR ALKYL BENZENE (LAB) 8,340 11,000
Normal paraffin ( normal grade)
Normal paraffin (heartcut grade)
Heavy normal paraffin 51,598 75,000
Light normal paraffin
Tar polymer
Heavy alkylate 840 840
Light Ends 1110 1110
PURE TEREPTHALIC ACID (PTA) 25,000 27,500
Paraxylene 20,840 20,840
Iso pentane
1,042 1,042
Normal pentane
IG benzene
Remax-1 50,509 50,509
Renine
Liquefied petroleum gases (LPG) (sr
2,250 2,250
grade)

2.3 The Process Description

The raw material Naphtha is used to produce Paraxylene an intermediate product.
Terephthalic acid (TA) is produced by the oxidation of paraxylene in the presence of
Acetic acid solvent with catalysts, in the presence of air. The following section describes
in brief the paraxylene process followed by the PTA and LAB processes.

The Para xylene process is divided into the following major sections;
 Naphtha pre-fractionation section
 Naphtha hydro-treating section
 Platforming section
 Continuous catalyst regeneration section

Reliance Industries Limited Page 7

  Xylene fractionation section
 Parex section
 Isomar section
 Tatoray section
 LPG Recovery

A brief description of the above process in given below;

 Naphtha Pre-fractionation Section: Feedstock to the paraxylene process is a
narrow cut Naphtha of 100 - 140 Deg C boiling range from refineries. Since
refinery is supplying straight run naphtha of boiling range 90-160 Deg C, this
Naphtha is fractionated in Prefractionation unit for the narrow cut.

 Naphtha Hydro-treating: The Naphtha Hydro-treating process is a catalysts

reforming process employing a select catalyst and Hydrogen rich gas stream to
decompose organic sulphur, oxygen and nitrogen compounds contained in
hydrocarbon fractions. In addition hydro-treating removes organo-metallic
compounds and saturated olefinic compounds. Hydro-treating processing is
commonly used to remove platforming catalyst poisons from heart cut Naphtha
prior to charging to the platforming process unit.

 Platforming Section: The hydro-treated naphtha from NHT unit is the feed to the
Platforming Section.

Major reactions taking place in the Platforming unit are as follows;

o Dehydrogenation of Naphthenes to aromatics-endothermic, promoted by
metal function of catalyst favoured by high reaction temp. and low
pressure
o Hydrocracking of paraffins-consumes hydrogen, exothermic, severe
hydrocracking reduces liquid yield
o Isomerisation: Midly exothermic, products subject to further reaction to
form aromatics or smaller paraffins.
o Dehydrocyclisation of paraffins to naphthenes: This reaction will precede
the dehydrogenation of naphthene to aromatics.

 Continuous Catalyst Regeneration Section (CCR): The Catalyst Regeneration

Section of a UOP Platforming Unit allows the refiner to operate the reaction
section at high severities with increased on-stream time by continuously
regenerating a circulating stream of catalyst from the Platforming reactors.
During a normal operating cycle, reforming catalyst deactivates due to
permanent and operating procedures, permanent poisoning can be avoided. The
Regeneration section continuously burns off the coke deposit and restores
activity, selectivity and stability to essentially fresh catalyst levels.

 Xylene Fractionation Unit: This unit consist of two distillation columns. The
function of the unit to prepare feed stocks for Parex and Tatoray urllts. The feed
from the platforming unit de-heptaniser is prepared in the xylene fractionation unit
clay towers. It combines with the clay treated feed from the bottom of BT splitter
column located in Tatoray unit and flows to the Xylene rerun column. In day
treated product from the isomar unit is also fed to the xylene rerun column. The
function of the xylene rerun column is to separate C8 aromatics from the heavier

Reliance Industries Limited Page 8

 material in the feed. The C8 aromatics are taken as the overhead product and
sent to the Parex feed. The net bottoms product from the xylene rerun column is
taken off on flow control upstream of the reboiler pumps and sent to the Tatoray
heavy feed rerun column. Tatoray heavy feed rerun column separates C9
aromatics for tatoray unit as overhead product.

 Parex Section: The UOP Parex process is a well-established, commercially

proven adsorptive separation method for the recovery of high purity para-Xylene
from C8 Aromatic fractions obtained from the overhead of xylene rerun column.
This uses a solid adsorbent, a zeolitic material of 20-30 mesh size, a liquid
desorbent, paradiethyl benzene and a flow directing device called, the “Coplanar
Manifolding Indexer” or CMI. Selective adsorption of para-Xylene is effected
according to the UOP Sorbex separation technology to produce para-Xylene with
a purity of 99. 7%. The process can economically recover 95-97% of the para-
Xylene in a single pass.

 Isomar Section: lsomar unit is to convert Metaxylene and Ethyl Benzene to para-
Xylenes and orthoxylenes. Isomar is a catalyst isomerization process to
efficiently convert mixture of C8 aromatics to a near equilibrium mixture. It
employs a Bi-functional noble metal spherical catalyst containing both add sites
(zeolite) and metal sites (Platinum) which operates in a pressure and
temperature range that favours para-Xylene and ortho-Xylene production from
Metaxylene and Ethyl benzene. In this process slight amount of Toluene is also
produced. However, the isomerisation is then subjected to fractionation to
remove light ends (C7) at the top. The bottom product which in rich in paraxylene
is recycled back to xylene fractionation unit for recovery of para-Xylene in Parax
Unit.

 Tatoray Section: The tatoray process is a catalytic process for trans-alkylation of

aromatics. In its simplest form, toluene is converted to Benzene and mixed
xylene. In actual operations, toluene and mixed C9 aromatics can be converted
to C6, C8 and C 10 at aromatics. The Tatoray unit has a fixed catalyst bed
reactor where the trans-alkylation reaction takes place. The Tatoray reactor is a
simple down flow type, it has an inlet distributor through which reactor feed is
directed and the effluent exists through an outlet basket placed at the bottom
port. Reactor temperature is the principle variable control conversion. Products
arc then separated through a series of distillation columns.

 LPG Recovery Unit: The LPG plant essentially consists of five major sections,
oFeed gas mixing section
oCompressor section
oDistillation column section
oMounded bullets LPG (tanker) loading gantry

Odourization of the LPG: As standard practice, all LP gases shall be odorized prior to
delivery to bulk plant by addition of a warning agent of such character that the gases
are detectable, by distinct odor to a concentration in air of not over one fifth the lower
Iimit of flammability.

Reliance Industries Limited Page 9

Purified Terephthalic Acid (PTA)

Purified Terephthalic Acid (PTA) is produced from, para-xylene in 2 stages;

 Oxidation Section
 Purification Section

The main reactions that take place in the reactor to produce TA are a series of
reactions which are given below:

Reliance Industries Limited Page 10

 Oxidation Section:

The Oxidation Process consists of three main sections: Air compression, Reaction,
Product Recovery and Solvent Recovery.

In the Reaction section p-xylene feed stock is mixed with acetic acid solvent and catalyst
solution. The combined charge is fed continuously to the reactor where it is reacted with
air. The major proportion of the terephthalic acid produced in the exothermic reaction gets
precipitated to form slurry in the reactor.

In the Product Recovery section, reactor product is de-pressurized and cooled in a series
of three crystallizing vessels. Precipitated terephthalic acid product is recovered by
continuous filtration incorporating a solvent wash stage. Residual acetic acid is then
removed in a steam tube rotating drier. The resultant product is conveyed either to the
intermediate storage, or directly to the purification plant.

In the Solvent recovery section, Impure solvent recovered from the Reaction and Product
Recovery sections, is partly recycled to reaction section and solvent is recovered from
part of the impure solvent. After the recovery, the residual slurry is incinerated in the
incinerator. The Oxidation section is designed for completely continuous operation. An
important feature of the plant is the facility to recycle a proportion of contaminated solvent
giving a “catalyst recycle” and thereby reducing the demand for fresh catalyst.

Reliance Industries Limited Page 11

 Purification Section:

The Terephthalic acid (TA) product from the Oxidation section contains a small quantities
of impurities which must be removed before the material can be used in the manufacture
of polyester. The principal impurity, 4 carboxy benzaldehyde (4CBA), an oxidation
intermediate, is hydrogenated to para-toluic acid. The para-toluic acid remains in aqueous
solution during the subsequent product recovery stages. This is achieved in the
Purification section by selective catalyst hydrogenation of an aqueous solution of TA
saturated with hydrogen at elevated temperature and pressure.

The purified terephthalic acid is subsequently crystallized and recovered by employing

solid/liquid separation and drying steps.

Reliance Industries Limited Page 12

Linear Alkyl Benzene (LAB) Process
The process of manufacture of Normal Paraffin mainly consists of following steps:
Pre-fractionation Section: This pre-fractionation section consists of the following two
distillation columns:
 Stripper Column
 Rerun Column
Fresh feed kerosene from storage tank is fed to the Stripper Column where the lighter
hydrocarbons are taken overhead. The Stripper Column bottoms are fed the Rerun Column
where the kerosene containing C10-C14 normal paraffin is taken overhead. This distillated
kerosene is sent to the hydro-treating section. The Stripper Column overheads and the Rerun
Column bottoms are returned to storage tanks.

The Hydrobon Process – Removal of Impurities from Kerosene: The Kerosene

feedstock with a boiling range of 170oC-250oC is mixed with recycle and make up hydrogen,
raised to reaction temperature and charged to the reactor section where sulphur, nitrogen,
oxygen and other metallic impurities present in the feed are eliminated by the use of UOP’s
high activity S-12 Hydrogen catalyst, Olefins if present in the feed, are saturated. The
presence of all these impurities would reduce the activity of the Molex molecular sieves. The
reactor effluent, after being cooled, passes into a high pressure separator from which recycle
hydrogen gas is withdrawn. The liquid stream is fed into a stripping column where C9-hydro
carbons are rejected overhead and C10 – bottoms are introduced into the Molex Unit.

The Molex Process Extraction of n-Paraffin: In this process n-paraffin are separated from
the non-normals by molecular sieves. The operation is carried out in a multi-bed adsorption
chamber fitted with a number of access lines, each attached to a distributor within the bed
and terminating outside the bed at a rotary distribution valves. The flow arrangement inside
the adsorbent chamber simulates a continuous counter current flow of liquid and solid
phases, without actual movement of the solid. The Raffinate and extract (n-Paraffin) streams

Reliance Industries Limited Page 13

that leave the sieve chamber are routed through the distributing device to their respective
fractionation columns where the de-sorbent, Raffinate and extract stream are separated.

n-Paraffin Prefractionation Unit: The N-paraffin stream from the Molex Units further pre-
fractionated to obtain the heart cut paraffin prior to feeding the Pacol Unit. This section
comprises a Stripper and a Rerun Column for removal of lighters (Stripper overhead) and
heaviers (Rerun Bottoms). The Rerun overhead (heart-cut) is then fed to the Pacol Unit.

The Pacol Process Dehydrogenation of n-Paraffin: The fresh and (recycle the detergent
alkylation unit) nC10 to nC13 paraffin are charged to the Pacol reaction section along with
recycle hydrogen. The reactor effluent is charged to a low pressure separator from which
recycle plus a small quantity of net hydrogen is withdrawn. The liquid phase from the
separator is fed to a stripping column. This column serves to remove traces of dissolved
gases and cracked products from the alkylation unit feed.

Detergent Alkylation Process: The mixture of C10-C13 n-Paraffin, olefins and fresh
benzene are combined with recycle benzene and fed to a two stage reactor section. The
reactor effluent passes to separating drums where the acid settle out and is returned to the
reactor. A small drag stream is charged to the HF regenerator from the first stage separating
drum. The regenerator bottoms consisting of very small quantity of polymer is withdrawn
from the bottom of the HF regenerator. The hydrocarbon layer from second setting drum is
heated and charged to the HF stripper. The stripper vapors are combined with the
regenerator vapors, then condensed and recycled to the reactor. The excess benzene is
recycled to the reactor section. The overhead paraffin are recycled to the dehydrogenation
unit. The bottoms flow to the Rerun and Recovery columns, in which the finished LAB is
taken as an overhead cut and heavy alkylate is taken at bottom.

Reliance Industries Limited Page 14

2.4 Captive Co-generation Power Plant (CCPP)
The requirement of steam and power for the process plant can be met by installing
high pressure boilers of suitable capacity. The concept of total energy envisages
production of one of the requirements e.g. steam as main condition while power
generation follows. In this situation, the steam demand is proposed to be met by Four
(4) high pressure coal/pet coke fired boilers each having a capacity of 250 TPH. This
combination can be used adequately to meet steam as well as power requirement.
Normally, 3 boilers and 4 STGs will be in operation. The steam parameters at super
heater outlet have been considered as 110 atm, 515oC in conformity with the steam
pressure level existing in the steam system. The power would be produced in 3x50
MW and 1 x 24 MW extraction/ condensing steam turbine generator. The technical
features of the proposed CCPP are enclosed as Annexure 2.

Reliance Industries Limited Page 15

 SECTION – 3

PLANT INFRASTRUCTURE & BASIC REQUIREMENTS

3.1 INTRODUCTION
The basic requirements for this proposal of debottlenecking as well as the expansion
of the CCPP are availability of fuel, water, land and other facilities like road, railhead
and transmission system for power evacuation. The debottlenecking proposal does
not envisage any additional infrastructure facility except augmented power. This
section discusses the requirements, vis-à-vis their availability at the proposed power
station site. The Coal / Petcoke based CCPP will have capacity 3x50 MW and 1x24
MW; necessary infrastructural facilities for the project will be added. Necessary space
provision for augmentation of auxiliary plant and infrastructural facilities has been
considered in the layout. The proposed plant will be located within PMD. The water
demand of the project shall be made available at plant boundary by water allocated to
PMD by MIDC and the Coal / Pet coke requirement would be met by indigenous or
imported sources. The power required for construction will be made available by State
Grid. The start–up and stabilization fuels will be natural gas.

3.2 LAND
The PMD is located within the MIDC allocated area of around 65.6 hectare. The
proposed debottlenecking shall be within the allocated land of MIDC. The MIDC
industrial area notification is attached at Annexure-3. The proposed expansion of
CCPP will be setup within PMD. There is space for CCPP inclusive of space
requirements for temporary storage yard as well. Other areas includes land
requirement of roads, drains / trenches, parking, transmission corridor, are already
available in the existing process plants. Suitable space for locating the Coal / Petcoke
based Cogeneration Plant was examined considering the following:
 Clear space availability.
 Logistics for Coal / Petcoke supply by trucks from Dharamtar Port
 Logistics for Ash disposal
 Distance of steam user
 Power evacuation
 Coal / Petcoke storage area is away from process plants to avoid coal dust
pollution.and maintaining safe distance from flare

The overall PMD layout is enclosed as Annexure – 4

3.3 WATER AVAILABILITY & REQUIREMENT

PMD has water allocation of 18960 m3/day from MIDC. This allocated quantity of water
from MIDC will suffice the requirement of the proposed project too. The major
requirement for water is in the CCPP which is for Cooling water, make-up water for
DM plant and other miscellaneous services such as fire-fighting and potable water
within plant. The estimated DM water recruitment and cooling tower make up is 1968
m3/day and 15456 m3/day for CCPP. The consumptive water requirement on the basis
of semi-open recirculating cooling water system using Induced draft cooling towers.

Reliance Industries Limited Page 16

3.4 RAW MATERIAL REQUIREMENT, AVAILABILITY & TRANSPORTATION
The raw materials for the PMD is heavy Naphtha / Reformate and Kerosene. These
raw material are pumped from BPCL / HPCL Refinery at Chembur to PMD through
dedicated pipeline. The required quantity is extracted from Naphtha and Kerosene and
the rest is pumped back to the Chembur refinery. The existing quantity at the PTA and
LAB plant is given below; there is no additional raw material required for this proposal
as this is only a debottlenecking activity and only modifications in the processes in
involved as mentioned in the earlier chapter.

Raw material Quantity (MT / month)

Naphtha 75,000
Kerosene 60,003

The proposed expansion of CCPP will involve Coal / Pet coke for Dharamtar Port near
Alibaug is proposed to be used for unloading and onwards movement of Coal /
Petcoke by trucks for transferring to PMD. It is estimated that about 117 TPH coal
needs to be required for the total power plant 3x50 MW and 1 x24 MW units. Natural
gas will be used only for cold start.

The annual Coal / Petcoke requirement for CCPP is 1 Million Tons / 0.61 Million Tons.
The fuel would be pre-crushed at supply end to (-) 250 mm. The daily coal
requirement with 100% PLF works out to about 2804 MT for the capacity of 3 x 50 MW
and 1 x 24 MW STGs. The limestone requirement for control of SO2 emission when
pet coke is used in the proposed CCPP shall be 0.32 MTPA max. The fuel analysis is
given below;

Heating Values (kcal/kg)

Pet Coke Coal
LHV 7672 4504
HHV 7895 4774
Ultimate Analysis (weight %)
Moisture 5 25
Ash 0.2 15
Carbon 80.07 51.45
Hydrogen 3.71 3.18
Nitrogen 1.37 1.04
Chlorine 0.63 0.01
Sulfur 7.33 0.7
Oxygen 1.69 12.89
Total 100 100
Proximate Analysis (weight %)
Moisture 5 25
Ash 0.2 15

Reliance Industries Limited Page 17

 Volatile Matter 14.22 17.80
Fixed Carbon 80.58 51.42
Total 100 100

3.5 POWER EVACUATION

Power generated, from the Co gen-CPP, is evacuated through HT cables on the pipe
rack. Also the system will be connected through suitable step up transformer to the
existing 100KV system or 220KV system as per the grid requirement. Power also be
evacuated to other Reliance Facilities located elsewhere through State and Interstate
grid network.

3.6 INFRASTRUCTURAL FACILITIES

All other infrastructural facilities essential for successful implementation of the project
in a shorter time frame are available. The existing access roads within PMD will suffice
the requirements of this proposed debottlenecking as well as CCPP. Skilled and
unskilled manpower will be required during construction and operation, adequate
accommodation will be provided to the manpower during construction period of CCPP.
Efforts will be made to employ local manpower based on skill set available. Coal/pet
coke will be transported by truck to the site using the available road connectivity,
Power required during construction will be drawn from the existing sub-station of
existing facility. Construction water would be supplied from existing water sources.
Other facilities such as Communication viz. telephone, fax, email and other
communication facilities etc. will be developed at an early stage for timely
implementation of the project.

Reliance Industries Limited Page 18

 SECTION – 4

ENVIRONMENT ASPECTS

4.1 INTRODUCTION
The debottlenecking of the above mentioned plant shall not add any additional
environmental load in the region. The proposed expansion of the CCPP will be
equipped with state-of-the-art pollution control devices to bring down the emission of
pollutants to a level well within statutory norms of the country. The proposed CCPP
will have the CFBC technology which uses lime injection for reduction of SO 2
emissions. This CFBC technology will also result is low NO X emission and the
adequate control mechanisms are in place to control the PM emission which will be
kept within statutory limits at all time.

4.2 ENVIRONMENTAL FACTOR

Air Emissions
The expected air emissions from a petrochemical complex are PM, SO2, NOx and
hydrocarbons (HCs/VOCs). Out of which, PM, SO2, and NOx are emitted continuously
from stacks (point sources) associated with fuel combustion as well as process units.
Besides small quantities of CO and HC will be released from process stacks. The area
sources of hydrocarbons release are through evaporation losses from storage tanks
and uncontrolled escapes from process units (fugitive emissions) i.e. by process vents,
leakages from pumps, valves and also from incidental spillages. Apart from impact due
to point and fugitive sources, there could be environment impact due to movement of
vehicles and construction. Therefore, the major air emission from this proposed project
are;
- Dust due to construction activities and flue gas from boiler
- Gaseous pollutants from in flue gas
- Fugitive emission due to handling of coal & ash

There will not be any additional stack due to this debottlenecking project. However, the
expansion of CCPP will envisage a new stack of 110 m height to disperse the
emissions adequately

Dust Particulates in Flue Gas

The electrostatic precipitators (ESP) proposed to be installed in this project would be
designed to limit the emission level of the particulate matter to 50 mg /m3

Sulphur Dioxide (SO2) in Flue Gas

Sulphur Dioxide from CCPP will be controlled through in situ Lime injection. A single (1)
multi-flue chimney of 110 m height is envisaged for the proposed power plant to meet the
dispersion of the emission adequately to meet requirement of AAQ norms.

Nitrogen Oxides (NOx) in Flue Gas

With the implementation of CFBC technology and low NOx burners the combustion
occurs in a multistage process due to which the temperature is lower consequently
reducing the NOx emissions.

Reliance Industries Limited Page 19

 Coal Dust due to Handling of Coal
Coal dust is likely to be generated at the conveyor transfer points, pet coke & coal
unloading area and fuel stockpile area. All these locations would be provided with dust
suppression facilities. Further, all conveyors would be provided with enclosed galleries.
The bottom portion of all the conveyor galleries would be provided with seal plates

Noise:
The major source of noise generation at shall be from process plants, CCPP, etc, In the
proposed debottlenecking there would be no increase in noise level . In proposed
expansion of CCPP proper precaution will be taken from design of equipment to
installation to keep noise level within prescribed limits.. The STG and other major noise
generating equipment’s will be provided enclosure for noise attenuation to reduce noise
level to 85 d B(A) at 1M distance.

Presently, at RIL-PMD the Noise levels are checked monthly during day time and night
time around the RIL-PMD Complex. The Noise levels are well within the prescribed limits.
The below schematic provides the noise monitoring locations;

Noise monitoring locations at RIL-PMD complex

Solid Waste Disposal:

The proposed debottlenecking proposal shall not generate any additional solid waste
including hazardous wastes. However, the proposed expansion of CCPP using coal/pet coke
will generate ash. The coal which shall be used for this proposed expansion will contain a
maximum of 15% ash. The pet coke which shall be used for proposed expansion will contain
0.2% ash. The Bed Ash of ~ 8 T/hr and the Fly Ash of ~ 31 T/Hr from the boiler is expected
and it will be taken to the ash disposal silos of adequate capacity. The ash will be utilized in

Reliance Industries Limited Page 20

construction & cement manufacture as per Ash utilization notification of MoEF. The
hazardous waste such as spent oil will be sent to authorize recyclers and waste such as
domestic waste comprising office waste shall be disposed of as per prevailing practice
adhering to MSW rules.

Water Pollution:
The proposed debottlenecking project shall not contribute to increase in effluents from
the complex. The present effluents are 5177 M3 / day is treated and disposed to CETP of
MIDC. The Effluent from LAB is treated and recycled as cooling tower make-up. The
effluents from CCPP are mainly;
- DM blow down water of ~ 4.1 m3/hr,
-Cooling tower blow down water of ~ 92 m3/hr,
- Boiler blow down water of ~1.25 m3/hr. (to be used for CT make up)
These wastewater shall be treated in a proposed RO system and will be re-used.

No additional sewage generation is expected from the project except during construction,
which will be treated in the existing ETP along with operating plant effluents as approved
by MPCB. The following description provides the details of the existing wastewater
treatment facility at RIL-PMD complex.

PTA Plant

The treatment consists of the following stages of operations:

 Equalization
 Anaerobic Treatment
 Aerobic treatment

Equalization: The effluent flow can vary in terms of both quality and quantity. To ensure that
treatment system operates at fairly steady condition, an equalization tank has been provided
to balance the flows from various sections of the plants in the PTA Division. The equalization
tanks are provided with an array of aeration grids and a common blower. Air is blown through
these to keep the tank contents in a homogeneous state. After homogenization in the first
compartment, the mixed effluent flows in the next compartment where it is mixed with
sewage. From here the effluent flows for Anaerobic and Aerobic treatment.

Anaerobic Treatment: The term “anaerobic treatment” implies a treatment process that is
carried out without oxygen. Anaerobic digestion (or fermentation) of organic matter is carried
out by a special mixed group of anaerobic microorganisms (bacteria). During the treatment
process, these microorganisms utilize the organic matter contained in the raw waste water as
a source of food and energy. As a result of their normal growth cycle, the micro-organisms
convert organic matter to a gaseous by- product called biogas and a small amount of new
cell mass.

In general terms, anaerobic digestion may be viewed as a three step process involving:
 Hydrolysis
 Acid formation
 Methane formation.

During the hydrolysis the insoluble organic matter is made soluble. Hydrolysis is carried
out by enzymes secreted from the micro-organisms (i.e. extra cellular enzymes) and
Reliance Industries Limited Page 21
 enzymes released from the micro-organisms upon death (i.e. intracellular enzymes).
These enzymes dissolve solid organic waste water particles so that bacteria can use
them as food. After the organic matter is made soluble, it becomes available as food for
the micro-organism in the next step.

The second step in anaerobic digestion is acid formation. Here , the soluble complex
organic ( i.e. cellulose , starches , proteins , fats and carbohydrates) is broken down bio
chemically into less complex organic matter ( i.e. sugars , amino acids and long – chain
volatile acids). These intermediate products are subsequently broken down further into
simple organic matter (i.e. short chain volatile acids- mainly acetic acid and propionic
acids). The micro-organisms which accomplish this breakdown of organic matter to
volatile acids are known as acid formers or acidogens.

The third step in anaerobic digestion is methane formation, which is carried out by
anaerobic microorganisms known as methane or methanogens. The methane formers
convert the volatile acids produced in the formation step into mainly methane (CH4) and
carbon dioxide (CO2). The methanogens depend upon the acidogens to supply volatile
acids so that they may produce CH4 and CO2 (i.e. bio-gas). The anaerobic digestion
steps occur simultaneously in the reactor as the acidogens and methanogens exist as a
mixed population in the reactor, environmental conditions for the most efficient operation
must be favourable to both. When balanced biological activity exists between the
acidigens and methanogens, the volatile acids produced during the acid formation step
are converted as rapidly as they are produced into biogas.

Aerobic system: The aerobic system consists of a two stage biological treatment. The
waste water from anaerobic treatment is routed through v-notch flow to first stage aeration
tank, where part of the suspended solids, dissolved organic solids etc. are subjected to
biological treatment by Activated Sludge Process. Aeration tank –I has been provided with
4 nos. surface aerators and Diffusers. The surface aerators and diffused aeration ensure
that the biomass in the tank remains in suspension and is uniformly distributed throughout
the tank volume for optimum stabilization of the effluent. Provision is made for the addition
of nutrients like urea and Di-ammonium phosphate which are required to ensure healthy
growth of the microbial mass in Aeration tank- I & II.

The wastewater overflowing from aeration tank-I is in partially stablised form. It contains
flocs of bio-mass that have to be separated. This is done in Secondary Clarifier –I. Part of
the Clarifier-I under- flow is pumped through the sludge conditioning tank and thickener
for the final disposal on sludge drying beds after de- watering through belt press filter.
The clarifier –I overflow passes to the second stage aeration tank-II along with the
overflow from Anaerobic System.

The Aeration tank-II is also provided with 3 surface aerators and Diffusers. The
wastewater overflowing from aeration tank-II is in a stabilized form. It contains floc and
bio-mass which are separated in Secondary clarifier-II . Part of the clarifier –II under flow
is pumped back to aeration tank-II as seed material. The excess sludge is pumped
through sludge conditioning tank and thickener for final disposal on sludge drying beds
after de-watering through belt press filter. The Clarifier –II overflow passes to the effluent
sump where boiler blow down, cooling tower blow down and DM plant regeneration waste
water are also discharged. The tank is also provided with a polishing surface aerator to
increase the residual oxygen level of the treated effluent before discharge into the
Common Effluent Treatment Plant.

Reliance Industries Limited Page 22

LAB Plant
The Effluent treatment cum Recycle Plant for Polyester & LAB Effluent is located in Fibre
complex. The Effluent generated in LAB Plant comprises process & utilities & along with
domestic sewage are pumped to Effluent Recycle Plant directly. The incoming effluent
characteristics is checked daily prior to the treatment. The detailed description of Effluent
Recycle Plant is presented below along with the schematic. The treatment scheme
comprises of the following unit operations and processes.
 Primary Treatment:
 Flow Equalisation / Neutralization
 Coagulation and Flocculation
 Dissolved Air Floatation / Cavitation Air Flotation
 Secondary Treatment:
 Activated Sludge Process
 Tertiary Treatment
 Polishing
 Chlorination
 Filtration

RAW
EFFLUENT FLASH DISSOLVED AIR
MIXER A FLOTATION
& FIRST
CAVITATION AIR AERATION TANK CLARIFIER
FLOATATION

HOLD TANK

FLOCCULATOR A

FLASH
MIXER B

HIGH
PRESSURE
TANK
FLOCCULATOR B
POLISHER

FINAL
CLARIFIER
TO SLUDGE
TO COOLING DRYING BEDS

TOWER
CHLORINE DI OXIDE DOSING
Ozone/CHLORINE CONTACT
ACF DMF TANK

Schematic Diagram of Effluent Recycle Plant

Reliance Industries Limited Page 23

Primary Treatment
a) Flow Equalization: Raw effluent is first collected in a Holding Tank to make the effluent
characteristics homogeneous. Air blowers ensure proper equalization of the effluent in the
Holding Tank. Alkali (NaOH) is dosed in the holding tank to neutralise the effluent. A pH
indicator, flow transmitter and controller interlocked with alkali dosing pumps are provided for
automatic pH control.

b) Coagulation and Flocculation: Effluent from the Holding Tank is pumped to the Flash Mixer
cum Flocculator A. Alum and Polyelectrolyte is dosed for coagulation and flocculation of the
colloidal impurities and for de-emulsification of emulsified oils in the Flash Mixer. A screen
type mechanical agitator is provided to ensure uniform mixing in the Flocculator Tank.

c) Dissolved Air Floatation (DAF): Effluent from the Flocculation tank overflows into the DAF
system. This system is designed to remove the oil and suspended solids from the effluent. In
this system the dispersion water, the water in which air is dissolved at high pressure, is
released at atmospheric pressure at the inlet of floatation tank so the air comes out of the
solution in the form of small bubbles which attaches themselves to the particles in the effluent
and carry them to the surface. Dispersion water is obtained by pumping water from the level
tank through a high pressure pump to an ejector where water is mixed with air supplied by a
compressor. Any solids in the water which fall to the bottom of the tank can be removed
through a drain valve. Scrapers are situated on top of the floatation tank to remove the solids
floating on the liquid surface. The clear liquid passes through a central pipe, into the Aeration
Tank.

Secondary Treatment- Activated Sludge Process (ASP): Aeration Tank and Secondary
Clarifier together constitute the Activated Sludge Process. This process is a continuously
mixed reactor (CSTR) - a biological treatment system characterized by a suspension of
aerobic micro-organisms, maintained in a relatively homogeneous state. The overflow from
the DAF enters the Aeration Tank. Aeration Tank uses mechanical surface aerators (five in
no., 50 HP each) which induce O2 transfer from the air to the effluent and at the same time
maintain the aerobic bacterial culture in suspension. The Aeration tank also has an online
Dissolved Oxygen Meter (DO meter). From the Aeration Tank the effluent enters the
Secondary Clarifier. The sludge is removed periodically (blow down) once in a day and sent
for drying. While the clarified outlet goes for tertiary treatment, the bottom sludge is
continuously under recirculation to maintain desired MLSS (Mixed Liquor Suspended Solids)
in the aeration tanks.

Tertiary Treatment
Polishing: The clear overflow from secondary clarifier is collected in a polishing tank, from
where it is pumped to flash mixer B. In flash mixer again Alum and Polyelectrolyte (PE) is
dosed into the water. The Flash Mixer B is connected to Flocculator B. The effluent from
flocculation tank flows into the Final Clarifier. The sludge generated is separated in the Final
Clarifier.

Chlorination: The clear overflow from clarifier flows to a Chlorine Contact Tank ( CCT).
Chlorine is bubbled in the mixing chamber of Chlorine contact tank for disinfection and

Reliance Industries Limited Page 24

chemical oxidation of organics. The construction of CCT is such that it increases chlorine
contact time. At the end of Chlorination Tank the residual chlorine in water is maintained
below 0.2 ppm.

Filtration: After CCT, Filter feed pumps are used to pump the effluent to Dual Media Filter
(DMF) followed by Activated Carbon Filter (ACF). Sand and Anthracite are used as the filter
media in the DMF. In DMF suspended solids are separated from water. In ACF, activated
carbon is used for adsorption of the impurities, especially residual chlorine, oil and grease is
removed. The Filter Backwash is recirculated back into the Equalization Tank. The treated
effluent is used as make-up water for Cooling Towers and for gardening.

4.4 POST OPERATIONAL MONITORING PROGRAMMEE

Regular monitoring of pollutants in different environmental disciplines like air, water, etc.
will be undertaken during the post operational phase of the plant. The monitoring
locations will be finalized in consultation with State Pollution Control Board.

Reliance Industries Limited Page 25

 SECTION – 5

PROJECT IMPLEMENTATION

5.1 PROJECT IMPLEMENTATION SCHEDULE

Successful execution of the project largely depends on the coordinated approach of
the project implementing agencies. Proper co-ordination between the various project
execution agencies, monitoring of project schedules, appropriate mobilization of
manpower and other resources can achieve effective cost control and timely
completion of the project.

The debottlenecking project is expected to be commissioned in 30 Months. The

proposed CCPP project would be having capacity of 3x50 MW and 1 x24 MW which is
expected to be commissioned within 30 months from the date of award of contract. It
is envisaged that the proposed project shall be executed by appointing a consultant for
the basic & detailed engineering including technical bid evaluations & the complete
Procurement & construction to be done by RIL.

The proposed coal/pet coke based power plant for installation would consist of the
following major equipments:-
a. Three Steam Generators, along with all ancillaries and auxiliaries, main stack
and all duct work, damper, chimney, suction air filters, silencers etc., along with
controls and instrumentation, suitable for base load operation with coal as the
main fuel.
b. Three (3) Steam Turbine Generator sets with deaerator & feed heating
equipment, steam condenser, CEP and feed water pumps with all piping
systems.
c. Other auxiliary systems and major equipment needed for the project:-
 Coal/petcoke Handling System.
 Ash Handling System.
 Cooling Water System.
 Fire Fighting Augmentation.
 Natural gas System
 AC & Ventilation System
 Electrical Distribution System
 Step-up & Aux. Transformers
 Illumination & Inter communication System
 Civil construction, mechanical and electrical erection services

5.2 PROJECT SCHEDULE

The salient features of the schedule are:-
i) Site preparatory work covering survey, leveling, grading to be completed and
construction facilities made available before the start of actual construction.
ii) Civil work including building and equipment foundations are to be completed
before the equipment arrives at site.

Reliance Industries Limited Page 26

 iii) Completion of Erection & Commissioning activity of the Main Boiler has been
indicated as twenty four (30) months after placement of order. Erection of
steam turbine would be completed in line with Main Boiler schedule so that, the
STG is ready for commissioning along with Main Boiler.
iv) The Civil works of Power Plant Building would be completed within ten (12)
months for taking-up the commissioning activities as per schedule. All auxiliary
systems such as CHP, AHP, plant water system, CW systems, fire fighting etc.,
needed for commissioning the plant should be suitably completed so as to
match the schedule for initial trial of the main equipment.

5.3 PROJECT MANAGEMENT

It is envisaged that an experienced and well-equipped project management group of
the Project Authority would be deployed to overview and steer the project through from
inception to commissioning. The team would co-ordinate and controls all the following
basic activities:-
i) Interfacing with different organizations entrusted with engineering, supply and
erection activities.
ii) Procurement activities covering control and monitoring of preparation of
specification, tender evaluation, negotiation, ordering, vendor drawing review
etc.
iii) Material Management & Quality Assurance.
iv) Supervision of construction and erection activities.
v) Preparation of Progress Reports & updating project schedule.
vi) Certification of Performance Testing and acceptance in association with
Consultant.
Simultaneously, a site office will be established which will co-ordinate the pre project
activities during conceptual engineering stage and later on take up supervision and
construction management during the construction stage. Basic engineering for the
equipment/systems may be carried out by an Engineering Consultants to be appointed
by the Project owner.

5.4 PROJECT MONITORING, CO-ORDINATION & CONTROL

5.4.1 Project Monitoring Information System

Progress of each activity at every stage would be physically monitored by respective
supervising engineers. All detailed information would be passed on to the Central
Monitoring Cell to keep track of the work progress. The detailed PERT / CPM network
for the project would be monitored on monthly / fortnightly basis to compare with
scheduled progress Vs actual progress achieved at site.

5.4.2 Co-ordination
Regular meetings would be held at site among the representatives of the Contractors,
the Consultants and the Engineers of Projects Department to review the progress of
each activity. At these meetings, slippages in progress would be identified and
corrective measures shall be taken. The problems arising out of site and material
constraints would be promptly sorted out. The meetings would also be attended to by

Reliance Industries Limited Page 27

 one of the senior executives of the company to facilitate on-the-spot decision. Minutes
of meetings would be circulated among all concerned for necessary follow-up action.
Co-ordination meetings between the Consultants and the senior executives of the
Project Authority would be held regularly for major decisions in regard to planning,
designing of various plant and equipment, execution procedures, manpower
deputations, industrial relations, security, etc. Steps would be taken to ensure regular
interactions between the Contractor, the Consultants and Projects Department.
Experienced site engineers will be working under the site manager at the site office.
The computer system set-up will allow close coordination with the home offices, which
will also be used for back-up and to solve any upcoming design issue. Owner will
organize and supervise construction work on site. Site activities of the subcontractors’
site teams will be coordinated by Owner to ensure that working areas are clearly
assigned and safe. Special emphasis will be put on the proper coordination of
interfaces between different packages to ensure, that erection and commissioning
work runs continuously and smoothly.

5.4.3 Reporting
Various reports would be generated in regard to the physical and financial progress of
the project on monthly, quarterly and yearly basis for forwarding to the various
Government Departments, Financial Institutions as well as for internal use. Daily
progress of the major items of work, along with their weekly/ monthly targets, would be
reported to the project head. The progress measurement system and weighting
according to various activities will be mutually decided and agreed based on the
Consultant’s proposal.

5.4.4 Financial Control

Actual cost records would be regularly monitored against forecasts, which would be
forwarded to Finance Department by the Projects Department on monthly, half-yearly
and yearly basis, depending on the actual progress of delivery and
erection/construction. Fund requirements would be assessed and arranged
accordingly.

5.5 OPERATION AND MAINTENANCE PHILOSOPHY

The objectives of plant operation and maintenance shall be to maximize the plant
output and availability with safe, reliable and efficient mode of plant operation, meeting
all regulatory requirements. Since the plant operation and control shall be achieved by
a modern state-of-the-art control and instrumentation system employing DCS MIS, the
plant O&M is proposed to be carried out by a limited number of highly qualified and
motivated operating staff. To achieve high degree of efficiency in plant management
and operation, proper training scheme consisting of in-house training as well as at
manufacturer’s work shall be developed during execution stage of the project. Beside,
the operators will be trained by the OEM specialists at their shop and at site to develop
requisite expertise for operation of the advanced class Boilers & STG in line with OEM
recommendation. The O & M staff would be in place during commissioning
stage so that they will be associated with the OEM team during pre-commissioning
stage of the units. The operation and maintenance of the station would be the overall
responsibility of the Plant Chief, who would be assisted by a team of experience
Executives and Operators in the respective field. Since the infrastructure for

Reliance Industries Limited Page 28

 maintenance of the specialized plant and machinery may not be readily available near
site, adequate maintenance facilities for day-to-day and minor plant maintenance
including a well-equipped workshop and trained technicians shall be developed for the
project. Major maintenance and annual overhaul will be contracted out to
manufacturers or reputed agencies. Odd jobs like, plant cleaning, hiring of vehicles,
road and drainage maintenance, plant security, gardening / green belt development
etc. will be locally contracted out.

Reliance Industries Limited Page 29

 SECTION - 6

PROJECT APPROVAL & CLEARANCE

6.1 GENERAL
In order to control and regulate the development of proposed project the legal frame
work developed by Government of India shall be followed. Accordingly, several
clearances and approvals shall be required to be obtained from different Government
and Statutory Agencies at various stages of development and operation at phase of
the project. Indicative list of Approvals / clearances to be obtained from Govt.
Authorities for this project are as below:

1. Environmental Ministry of Environment, Forest &

Climate Change (MoEF & CC)
2. Consent to Establish Maharashtra Pollution Control
Board (MPCB)
3. Boiler Pressure Parts Chief Inspector of Boiler
4. Plant Installation Factory Inspectorate
5. Electrical Installation Electrical Inspectorate
6. Construction Labour Labour Commissioner
7. Fire Fighting Insurance Authority and Local
Authority

Reliance Industries Limited Page 30

 SECTION - 7

PROJECT COST ESTIMATE

The proposed debottlenecking process will be carried out at a capex of Rs. 340 Crs. for PTA
plant and 200 Crs. for LAB plant. The capex for the CCPP is envisaged at Rs. 1250 Crs.
Therefore, the total Capex envisaged for this proposed project is Rs. 1790 Crs.

Reliance Industries Limited Page 31

 Annexure-1

Topo Sheet Showing location of RIL-PMD/Project Location

Reliance Industries Limited Page 32

 Annexure-2

Brief Technical Features of 3x50 MW and 1x24 MW Captive Cogen Power Plant (CCPP)
at RIL Patalganga and Efficiency improvement of the existing Gas turbines from 24MW
to 33MW.

Reliance Industries limited intends to put up a coal based 3x50 MW & 1x24 MW Captive
Cogeneration Power Plant (CCPP) to cater to the power and process steam requirement of
their existing two units of PTA plant and Polyester plant and Efficiency Improvement initiative
for existing Gas Turbines (2x 24MW) to increase the power output to 33 MW (Each).These
two units of the Petrochemical Plant complex are located at Patalganga near Mumbai. The
project shall comprise 4x250 TPH high pressure boilers and 3x50MW & 1 x 24 MW steam
Turbine with associated auxiliary systems such as, condensers, CW system (Cooling
Towers, C.W. Pumps, Auxiliary C.W. Pumps), Effluent Treatment Plant (ETP), Electrical
Distribution System, Instrumentation & Control system, Inter connection of H.P. steam supply
header of STGs, Deaerators, Boiler Feed Water Pumps, ESP, multiflue chimney, Electrical
distribution system, Instrumentation & control system, steam supply piping and pipe cum
cable rack up to the interconnection of existing process steam header. Other utilities such as
DMW, compressed air (I.A. & S.A.), C.W. F.W. (Filtered Water) and water for hydrants of fire
protection system shall be tapped from the existing plant. Other utilities such as compressed
air (I.A. & S.A.), C.W. F.W. and water for hydrants of fire protection system shall be tapped
from the existing plant.

The brief technical features of various equipments for Mechanical, Electrical Systems are as
follow:

1.0.0 Mechanical
1.1.0 Boilers: CFBC boilers, 4x250 TPH, Each boiler shall be operating at 110.0 kg/cm2g
pressure and temperature of 520 +/- 5 degree C at the superheater outlet. Normally
these boilers shall be operating on imported coal. However, these boilers shall be
capable of operating on petcoke as well. Various Draught Fans (ID, SA and PA) for
the Boilers shall be provided with VFDs. These Fans shall be 2x50% capacity with
20% margin on flow and 44% margin on head for each Boiler. Natural Gas (NG) at 5.0
kg/cm2g shall be provided for the boiler start up and for drying of lime stone. Suitable
HP and LP chemical dosing systems shall be provided.

1.2.0 ESP: Particulate matter in flue gas at outlet of each ESP with one field out of service
at BMCR shall be </= 50mg/Nm3.

1.3.0 Chimney: One (1) RCC multiflue chimney common for all three boilers in Phase-1. The
height of the chimney shall be minimum 110 m considering worst fuel (Petcoke with
high sulphur content) as per MOEF norms. Sox level shall be limited to </= 400 ppm
and NOx level shall be limited to </= 100 ppm.

1.4.0 De aerators: 2x375 TPH Spray cum tray type. Shell and head of boiler quality material
and trays of SS-304 material. Deaerator storage tank shall have minimum 10 minute
storage (between maximum and minimum water levels) at BMCR + return condensate

Reliance Industries Limited Page 33

 from process plant. De aerators operating temperature is maintained at 150 degree C.
Equalizing arms between two De aerators shall be provided on water and steam side.

1.5.0 BFW Pumps with Hydraulic couplings: 5x100% capacity BFW Pumps (4W +1S) and
1x100% capacity BFW Pump (1W).

1.6.0 Feed Control Stations: 2x100% with 1x30% capacity feed control stations at inlet to
the boilers shall be provided.

1.7.0 Process steam parameters at the battery limit are as follow:

i) Maximum Flow- 240 TPH at 100 bar(g) and 490 degree C
ii) Minimum Flow- 120 TPH at 100 bar(g) and 490 degree C
iii) Maximum Temperature- 510 degree C

1.8.0 Fire Detection and Protection system-

i) Water for Fire protection system for Boilers area as well as for STG area shall be
tapped from the existing fire hydrant system. Suitable fire detection system for
Boiler area as well as for STG area shall be provided.

ii) Independent fire detection and protection system for coal stockyard area shall be
provided consisting of Fire Water cum Raw water storage Tank, Motor operated
and diesel engine operated Fire water Pumps, Jockey Pumps, Fire hydrants and
Fire detection system.

1.14.0 Condensate Polishing Unit (CPU): CPU shall be added to treat hot and cold process
condensate return from the process plant. This unit shall consist 1 (one) Condensate Storage
Tank (180 m3 capacity), Plate type heat exchangers, CPU and condensate transfer pumps.

1.15.0 Steam Turbine Generators & Auxiliary systems

i) 1x 24 MW & 3x50 MW Steam Turbines shall be of single casing, horizontal,
extraction cum condensing type, operating on fixed pressure mode of operation.
ii) Turbine oil cooling system shall be provided.
iii) Turbine oil purification system shall be provided. It shall consist of one no.
centrifuge, 2x100% lube oil pumps, Lube oil tank & piping of SS construction and
Duplex type SS oil filters.

1.16.0 Steam Condenser-Horizontal water cooled shell & tube type two pass condenser with
2 minutes hot well storage capacity and condenser exhaust pressure of 76mm Hg
shall be provided with Condenser shell of boiler quality plates and Tubes of SS -304.

1.17.0 Condenser air extraction system consisting of 2x100% steam air ejectors and 1x100%
Hogging ejector shall be provided.

1.18.0 Condensate extraction Pumps-2x100% pumps per unit, vertical, mixed flow,
centrifugal design, can type with mechanical sealing arrangement shall be provided.
Capacity shall be based on maximum steam flow at turbine exhaust during VWO
operation and drains with 3% makeup and 10% margin.

1.19.0 LP Feed Water Heaters-2nos. LP feed water heaters (shell & tube type) for each unit
with C.S. Shell and SS -304 Tubes shall be provided.
Reliance Industries Limited Page 34
1.20.0 HP Feed Water Heaters have not been envisaged since BFW Pumps are located quite
far away (~ 500m away) in the Boilers area.

1.21.0 Cooling Tower (CT): One Induced draft, counter flow type, Cooling Tower shall be
provided, common for two units. The Cooling Tower shall have Six (6) cells (with back
to back arrangement), with a range of 9.0 degree C and approach of 4.5 degree C.
The Cooling Tower shall be provided along with suitable flow control valve in the inlet
make up water line and level switches in the CT basin.

1.22.0 CW and ACW Pumps and piping: Five (8) CW pumps (7W + 1S) and three (5) ACW
Pumps (4W +1S) shall be provided for both units along with the buried CW piping
system.

1.23.0 Side Stream Filters (SSFs): Two (2) (1W +1S) SSFs shall be provided, each sized for
3% of Total CW and ACW flow.

1.24.0 Potable water system: Three (3) Sintax Tanks each of 5 m3 capacity shall be provided
one each in STG area, Boiler area and in Coal Stockyard area - along with the
distribution piping.

1.25.0 Existing Gas Turbines are site rated to 24MW capacity based on the de-rating of Gas
turbines to local Ambient Conditions and Aging/Fouling of the Compressors, by
replacing some of the Parts of the Gas turbines and Changing the control System
software it is possible to increase the capacity of the Gas turbines from 24MW each to
33 MW each.

2.0.0 Electrical System-

2.1.0 General

Power generated from the 1x24 MW & 3x50 MW units will be hooked up to
extended feeders of existing 22kV ENC switchgear. Further evacuation of
power will be through existing 22kV feeders from the same switchgear to
various process plant equipments. The auxiliary power required for the 1x24
MW & 3x50 MW power plant will be derived from same 22kV ENC switchgear
along with necessary step down transformers and associated 6.6kV and 415V
switchgears.
Power generated, from the Co gen-CPP, is evacuated through HT cables on the
pipe rack. Also the system will be connected through suitable step up
transformer to the existing 100KV system or 220KV system as per the grid
requirement..

2.2.0 Description of Auxiliary Power Distribution:

The generator will be directly coupled to the respective steam turbine and shall
have a nominal rating of 24 MW & 50 MW at 0.8 (lag). Generation level shall
be 11 kV, 50 Hz, 3 ph. The generator shall be connected to the 22 kV
switchgear bus through respective 62* MVA, 11kV/22 kV generator transformer.
Connection between generator and generator-transformer low voltage terminal
shall be done by segregated phase bus duct and that between the high voltage
terminal of Generator Transformer and 22kV switchgear shall be done by H.T
Cable. Two voltage levels viz. 6600 volts and 415 volt have been envisaged to

Reliance Industries Limited Page 35

 supply power to plant auxiliaries. At Powerhouse 6.6kV unit power board is
envisaged for supplying the total auxiliary loads of the respective unit of the
power plant. This 6.6kV switchboard at power house shall be fed from Existing
22kV ENC Switchgear through two nos. adequately rated 22/6.9kV station
transformers. This 6.6kV switchboard shall cater to total auxiliaries of unit like
ID fan, FD fan, BF pump, etc., unit L.T loads, ESP loads, Ash handling plant,
through required number of 6.6kV breakers, 6.6/0.433kV transformer & 415V
PCC and MCC’s.

The secondary of Station transformer shall be connected to 6.6kV switchgear

through 6.6kV (UE) grade cables. And total auxiliary loads for the plant shall be
fed from the 6.6 kV switchboards located in Boiler area. 415V PCC shall
receive power from the 6.6kV boiler area switchboard through 6.6/0.433 kV LT
auxiliary transformers. Different MCCs for the plant LT loads shall be connected
with the 415V PCC of the boiler area through cables. A reliable DC power
source shall be provided to supply those loads which are required to function
for security, protection and safe shutdown of plant in the event of failure of
normal AC power supply. Each unit shall have one (1) 110V battery set of
adequate capacity for the total DC loads of the unit. 110V D.C. battery and
D.C. panels will be provided for the D.C. power supply. And batteries will be NI-
Cad type. Normal requirement of the battery is to supply power for the
following: Control and monitoring of the plant & Alarm and annunciation of
plant condition under emergency. Capacity of the 110 V battery sets will meet
the requirement of the total loads. Uninterruptible power supply system of
continuous duty have been envisaged to supply regulated, filtered and
uninterrupted 110 V, 50 Hz, single phase power within acceptable tolerances to
critical AC loads like computerized data acquisition system, microprocessor
based control and instrumentation system, control systems, annunciation
system, indicators/recorders mounted on unit control boards and other critical
loads of such nature. The emergency power system provides power to
essential auxiliary loads required to permit a safe shut down of the unit in the
event of a plant blackout. In addition, power is provided for auxiliaries and
services required for personnel safety and minimum plant maintenance during
the blackout. Emergency MCC shall be provided for emergency loads. C Lube
Oil Pump, turning gear motor, vapour extractor motor, Charger for DC system
and UPS system loads are generally connected to the emergency MCC.

Reliance Industries Limited Page 36

 Annexure-3

MIDC Industrial Area Notification

Reliance Industries Limited Page 37

Reliance Industries Limited Page 38
Reliance Industries Limited Page 39
Reliance Industries Limited Page 40
Reliance Industries Limited Page 41
 Annexure-4

Overall Plot plan

Area for 3x50MW and 1x24

MW steam Turbine.
Area of the
Existing gas
PTA Plant Turbines
(2x24MW)
LAB Plant

Coal & Ash Storage Area

Area for CFBC Boilers (4 X
250 TPH), De aerator and
Feed pumps

Reliance Industries Limited Page 42