EIA & RA STUDY FOR WAX PROJECT AT NUMALIGARH REFINERY LIMITED

Project & Process Description

2.0

PROJECT & PROCESS DESCRIPTION

Numaligarh Refinery processes Assam crude mix, which is highly paraffinic (8% on crude) and
has high wax content. M/s NRL engaged M/s IIP, Dehradun, to carry out study for commercial
production of paraffin and semi-microcrystalline wax. Accordingly, M/s IIP, Dehradun carried
out probe runs on a number of sample feed stock provided by NRL, on lab scale. This was
followed by bench scale experiments at IIP to determine the filterability of various stocks,
achievable quality of product wax as well as optimum operating parameters. Having received
the results from M/s IIP Dehradun, which were encouraging and promising both in the lab and
bench scale study respectively, M/s NRL engaged the services of M/s EIL for preparing a
Detailed Feasibility Report (DFR) for setting up a grass root De-waxing/ De-oiling Unit for the
production of Paraffin and Semi-Microcrystalline Waxes (SMCW) at NRL, Numaligarh.
Following the DFR prepared by M/s EIL, M/s NRL proposes to set up 43,300 TPA of Type-1
Wax and 4500 TPA of Micro Crystalline Wax within existing refinery from MVGO and HVGO
feed. As per earlier schedule, the project was to be mechanically completed in 49 months. But
due to some advance action initiated, the revised schedule is of 42 months from the date of
approval, out of which 2 months have been considered for commissioning activities.
This project is proposed to be implemented on Engineering Procurement & Construction
Management (EPCM) basis wherein NRL shall engage consultants for process design,
detailed engineering, procurement, inspection and expediting. Construction supervision at site
and commissioning assistance, placement of orders and award of contracts shall be done by
NRL. Time schedule of 42 months for implementation of project has been envisaged from the
zero date i.e., the date of Go Ahead after receipt of process packages for units, viz., De-oiling
and De-waxing Unit and Hydro Finishing Unit and connected utility offsite packages.

2.1

NUMALIGHRAH REFINERY

2.1.1

Configuration
The refinery configuration has been selected based on the following objectives:
a. Value addition for the product slate per unit of investment
b. Maximum production of middle distillates to meet the deficiencies in the country in general
and North-eastern and northern regions in particular.

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c. Minimum fuel oil production
d. Up-gradation of the residue to the maximum possible extent and with scope of
manufacturing more products in future.
e. Quality of the products and proven / established technologies
Considering various alternatives, the Hydrocracker technology has been selected for the
secondary processing unit for production of premium quality SKO/ATF & HSD.
2.2

PROPOSED PROJECT
The proposal relates to set up a grass-root De-waxing / De-oiling Unit for production of paraffin
and SMCW at existing refinery. Following new units have been envisaged for the proposed
project:

2.2.1

De-waxing & De-oiling Unit

Hydro-finishing Unit

Slabbing & Washing Unit and

Warehouse

Feed Characteristics
The feed obtained from Vacuum Distillation Unit for the proposed project have following
characteristics:
Feed
MVGO
HVGO

2.2.2

TBP Cut (oC)

351.6-485.7
344.-581.7

Feed Rate
28.20 TPH
23.32 TPH

Product Details
The following products would be produced in blocked out mode:
Products
Paraffin Wax
Semi Microcrystalline Wax

Type
I
A

Capacity
43,300 TPA
4500 TPA

On-stream days
260
40

Alternatively,
Products
Paraffin Wax

Projects & Development India Limited, Sindri

Type
I

Capacity
50,000 TPA

On-stream days
300

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2.2.3

Product Characteristics
The characteristic of the end product is as under:
Product
Paraffin Wax
Semi Micro-crystalline

Type
I
A

M. Pt. (oC)
61.0
67.0

Oil Content (Wt. %)

0.1
0.3

Specification
BIS:4654-1593
BIS:13833-1993

(a) Paraffin Wax

Paraffin is the common name for the hydrocarbons with general formula CnH2n+2 (Alkanes). It is
mostly found as a white, odourless, tasteless, waxy solid, with a typical melting point between
470C to 640C and having a density of around 0.9 g/cm3. It is insoluble in water, but soluble in
ether, benzene and certain esters. Paraffin is unaffected by most common chemical reagents,
but burns readily. It is an excellent electrical insulator, with an electrical resistivity of between
1013 and 1017 ohm meter.
Paraffin wax (C25H54) is an excellent material to store heat, having a specific heat capacity of
2.14-2.19 Jg-1K-1 and a heat of fusion of 200-220 Jg-1. This property is exploited in modified dry
wall for home building material. It is infused in the dry wall during manufacture so that, when
installed, it melts during the day, absorbing heat, and solidifies again at night, releasing the
heat. Paraffin wax is used in making Candles, Textiles, Cosmetic, Yarns, Plastic, Paper, Rope,
Pencil, Waterproofing, Packaging and even in some food stuffs.
(b) Semi Microcrystalline Wax
Semi Microcrystalline Waxes are derived from the refining of heavy distillates from lubricant oil
production by de-oiling petrolatum (petroleum jelly) as a part of the petroleum refining process.
Depending on the end use and desired specification, the product then may have its odour
removed and colour removed. This is usually done by means of a filtration method or by hydrotreating the wax material.
In contrast to the more familiar paraffin wax which contains mostly un-branched alkanes,
microcrystalline wax contains a higher percentage of iso-paraffinic (branched) hydrocarbons
and naphthenic hydrocarbons. It is characterized by the fineness of its crystals in contrast to
the large crystals of paraffin wax. It is generally darker, more viscous, denser, tackier, and
more elastic than paraffin wax and has a higher molecular weight and melting point. The
elastic and adhesive characteristics of micro crystalline waxes are related to the non-straight

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Project & Process Description

chain components which they contain. Typical semi microcrystalline wax crystal structure is
small and thin, making them more flexible than paraffin wax. It is commonly used in cosmetic
formulations.
Microcrystalline waxes can generally be put in two categories: Laminating Grades and
Hardening Grades. The laminating grades typically have a melting point of 140-1750F and
needle penetration of 25 or above. The hardening grades ranges from about 175-2000F and
have a needle penetration of 25 or below. Colour in both grades can range from brown to
white, depending on the degree of processing done at the refinery level.

2.3

PROCESS DESCRIPTION

2.3.1

Flow Diagram of NRL

A Flow Diagram of refinery is depicted below:

CRUDE
GAS
LPG
NAPHTHA
ATF
SKO
HSD
(BS-II, EURO III)

CDU
(3.0 MMTPA)
MSU
(225 TMTPA)

MOTOR SPIRIT
(BS-II, EURO III)

RCO

LVGO

HCU
(1.1 MMTPA)

MVGO
HVGO
VR

DCU
(0.306 MMTPA)

COK. DIST.

H2

SOUR GAS

SRB
(4.0 TMTPA)

H2U
(38 TMTPA)
RPC

SULFUR

SOUR WATER

CCU
(0.1 MMTPA)
CPC

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Project & Process Description

2.3.2

Process Description of Proposed Wax Project

The function of the de-waxing / de-oiling unit is to produce Paraffin and SMC Waxes from two
different feed stocks in blocked out operation employing MIBK as the de-oiling solvent (> 98%
purity, commercial grade).
The two designed feed stocks for the unit are:
(1) MVGO obtained from Vacuum Unit
(2) HVGO obtained from Vacuum Unit
Wax re-crystallization, such as wax sweating, separates wax into fractions and the process
makes use of the different solubility of the wax fractions in a solvent such as ketone.
More generally, 3 main molecules are used in modern refinery technology:
1. Solvent de-waxing in which the feedstock is mixed with one or more solvents, then the
mixture is cooled down to allow the formation of wax crystals, & the solid phase is
separated from the liquid phase by filtration.
2. Urea de-waxing, in which urea forms adducts with straight-chain paraffin that was
separated by filtration from the de-waxed oil.
3. Catalytic de-waxing, in which straight-chain paraffin hydrocarbons are selectively
cracked on zeolite-type catalysts, and the lower boiling reaction products are
separated from the de-waxed lubricating oil by fractionation.
The proposed wax plant has selected the process of solvent de-waxing by using Methyl Isobutyl Ketone (MIBK) as solvent which would be recycled in the process.
The proposed wax plant shall have following main units:

(I)

I.

De-waxing and de-oiling unit

II.

Hydro-finishing Unit

III.

Slabbing & Washing Unit and warehouse

De-waxing and de-oiling unit

The De-waxing / De-oiling Unit of proposed wax project consists of following six sections:
a) Chilling Section
b) Filtration Section

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c) De-waxed Oil Solvent Recovery Section
d) Slack Wax Solvent Recovery Section
e) Refrigeration Section
f)

Inert Gas System

(a) Chilling Section

In Chilling Section, the feed obtained from storage is first heated above its cloud point in order
to dissolve any precipitated waxes which may be present. The feed heating is done in the LP
Steam Heater where the feed is heated to 70-800C. This is followed by controlled cooling and
chilling of the feed in the subsequent exchangers. The feed cooling circuit consists of a feed
cooler to cool the feed to nearly 550C using cooling water before feeding it to the DP
Exchanger/ Chiller train. Feed temperature to DP Exchanger/ Chiller trains is maintained by a
temperature controller, provided down-stream of feed cooler. Feed chilling up to filtration
temperature (50C) is done in two parallel trains of DP scrapped surface exchangers followed by
two parallel trains of chillers. Primary filtrate obtained from primary filters is used as the chilling
medium in DP exchangers. Final feed chilling is done in DP chillers, which employ refrigerant
for achieving the desired cooling. During feed chilling, dilution solvent is added at various
points along the DP exchanger/ chiller trains to reduce the viscosity of the charge mix and
hence the pressure drop in the chilling trains. The dilution temperature is kept nearly the same
as the charge mix temperature at the injection point. Re-pulp filtrate is used as dilution solvent.
(b) Filtration Section
The wax crystals are separated from the chilled feed by primary filters. The re-pulp or
secondary filter performs the second stage filtration in order to further reduce the oil content in
wax to the desired level. The liquid to solid ratio of the feed to primary and secondary filters is
adjusted by filtrate recirculation to promote easier filtration. The chilled charge mix obtained
from DP exchangers and chillers flows to primary filter feed drum which is blanketed with inert
gas. The feed to each individual primary filter flows by gravity from the drum. The vacuum
produced by inert gas vacuum compressor draws the filtrate through the filter cloth and
deposits the wax crystals on the filter cloth during the filtering of the cycle. The primary filtrate
is pumped by the primary filtrate pump to the chilling section for cold recovery. The inert gas

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from primary filtrate receiver flows to the inert gas compressor through inert gas drip pot to
eliminate any entrained liquid.
The wax cake formed on the filter cloth is washed with chilled solvent as it emerges from the
liquid slurry. Following cake washing, the cake is dried by inert gas drawn through the filter
cloth. The dry cake is then discharged with blow gas to rotating scroll conveyer which takes
wax to wax boot. The dilution solvent is added to the boot for wax re-pulping. This serves two
purposes. Firstly, it helps in washing additional oil from the wax and secondly it renders the
slurry sufficiently fluid for pumping. The primary wax mix from primary filters is pumped by the
respective primary filter boot pumps to the secondary filter. The slurry is diluted with recycled
secondary filtrate in order to achieve the desired liquid to solid ratio. During filtration, the
secondary filtrate obtained is collected in the secondary filtrate receiver where it is refrigerated
from inert gas. The secondary filtrate is pumped by secondary filtrate pump to chilling section
for incremental dilution and to the secondary filter feed for feed dilution.
The wax cake is washed, dried and collected in the secondary filter boot as is done in the
primary filter. The wax mix drawn from the secondary filter boot is pumped by the filter boot
pumps to slack wax solvent recovery section after being heated in the wax mix MP steam
heater. A part of the heated wax mix is recycled back to the individual secondary filters boot to
maintain the desired operating temperature and hence fluidity of wax slurry for pumping.
Provision has been kept in the design for cold backwashing of the primary as well as
secondary filters. This will help in reducing the frequency of filter hot washing and hence filter
down-time. Secondary filtrate drawn from secondary filtrate receiver is used for cold backwashing of the filters by cold back wash pumps. The cold back washing of the filters is done
periodically and can be accomplished during normal running without interfering with filtration
operation.
(c) De-waxed Oil Solvent Recovery Section
The de-waxed oil (DWO) solvent recovery section consists of three stages, flashing followed
by steam stripping. The different stages are to be operated at the following conditions:

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Stages
Atm. Flash
MP Flash
HP Flash
Steam Stripping

Operating Pressure (Kg/cm2a)

1.34
2.8
4.2
1.2

The primary filtrate from feed mix chilling section is sent to DWO solvent recovery section to
recover solvent from the de-oiled wax. Here the primary filtrate is first preheated by solvent
vapours obtained from atmospheric and pressure flash columns in exchanger and followed by
final heating in the LP steam heater before feeding to the atmospheric flash column, MP flash
column and HP flash column, join after exchanging heat in exchangers and are sent to the
Atmospheric Solvent Cooler where liquid solvent is cooled to 400C. The cooled solvent and
water from solvent cooler is routed to solvent water separator drum where solvent and water
are separated. The solvent flows to dry solvent receiver whereas the water containing
equilibrium quantity of solvent is sent to Azeotrope Column after being heated by Azeotrope
Colum Feed Bottom Exchanger. Solvent contained in Azeotrope Column is stripped off by
steam and the solvent vapours along with steam and condensed in solvent condenser and
routed to solvent water separator.
Fresh make-up solvent is pumped to dry solvent receiver drum by make-up solvent pump. Dry
solvent is sent to chilling and filtration section by solvent dilution and reflux pump.
The de-waxed oil obtained from the bottom of atmospheric flash column is pumped by the
DWO atmospheric flash bottom pump to DWO MP flash column after preheating in DWO mix/
HP flash vapour exchanger followed by DWO Mix/ Foots oil exchanger. The separated vapours
from column top are also sent to atmospheric solvent cooler after exchanging heat with primary
filtrate in exchanger. The bottom liquid from column is routed to DWO HP flash column
through pump after preheating in DWEO mix heater. The HP flash column operates at 4.2
Kg/cm2 a pressure. The liquid from HP flash bottom is fed to DWO stripper under its own
pressure for final solvent stripping. The solvent vapours from HP flash column are sent to
atmospheric solvent cooler after exchanging heat with MP flash column feed. Vapours from
DWO stripper are routed to solvent condenser. In DWO stripper the last traces of the solvent
are recovered by steam stripping. The de-waxed oil from the stripper bottom called Foots Oil is

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sent to storage tank through DWO stripper bottom pump after heat recovery and cooling in the
DWO Mix/ Foots Oil exchanger and finally to Foots Oil Cooler respectively.
(d) Slack Wax Recovery Section
The slack wax solvent recovery section consists of single stage flashing followed by steam
stripping. The different stages are to be operated at the following conditions:
Operating Pressure (Kg/cm2 a)
Flash Column

1.3

Steam Stripping

1.2

The wax mix after preheating in wax mix LP Steam is routed to wax mix surge vessel which is
equipped with heating coil. The wax mix is pumped by wax flash column feed pump to slack
wax flash column after pre-heating in a series of exchangers. The wax mix is first pre-heated
by SW mix flash vapour exchanger and finally by MP steam in exchanger. The flashed solvent
recovered from column top after heat recovery is routed to Atm. solvent cooler. The wax mix
obtained from column bottom is fed by gravity to wax stripper. The last traces of solvent are
recovered in the stripper by steam stripping. The wet solvent vapours from stripper top are
routed to solvent cooler and then to solvent separator for further processing. The wax product
obtained from stripper bottom is sent to storage through wax stripper bottom pump after being
cooled in tempered water cooler.
In solvent water separator the wet solvent from various sources is collected and water &
solvent phases are allowed to separate. The water rich phase is pumped to waste water
stripper column through column feed pump. The stripped solvent vapours obtained from
column top by steam stripping are condensed in solvent condenser and routed to solvent water
separator drum. The waste water obtained from waste water stripper column bottom is routed
to oily water sewer (OWS).
(e) Refrigeration Section
The typical refrigeration cycle serves as a utility to provide the chilling medium for the feedstock and the solvent. Refrigerant R-22 is proposed to be used as refrigerant and is utilized for
the following purposes:
a) Charge mix chilling in the DP chillers
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b) Solvent chilling solvent chiller
c) Inert gas chilling in IG chiller
(f) Inert Gas Section
This section consists of the following facilities:
a) Inert Gas Generator
b) Inert Gas Holder
c) Inert Gas Compressor
The inert gas is primarily used for filtration and remains in circulation in a closed loop
comprising of primary and secondary filters, Primary and Secondary Filtrate Receivers, Inert
gas pot and inert gas vacuum compressor. Inert gas is also used for blanketing purposes in
filters, solvent tanks etc. This prevents solvent losses as well as fire hazards by eliminating the
contact of solvent with air.
(II)

Hydro-finishing Unit (HDFU)

The objective of the hydro-finishing unit is to obtain a Type-I paraffin wax from the wax exMVGO, as per BIS 4654:1933.
This unit will also produce Type -A micro-crystalline wax (MCW) from wax ex-HVGO as per
BIS 13833:1993.
Hydrogenation is performed under pressure, in a fixed bed reactor over a specific catalyst.
Products
Paraffin Wax
Semi Microcrystalline Wax

(III)

Type Drop Melting Point (0C)

I
45-75
A
65-70

Specification
BIS 4654:1933
BIS 13833:1993

Slabbing & Washing Unit

Wax produced shall be taken to Slabbing & Washing unit where the final product will be made
in the form of slab for subsequent weighing, packing and storage.

2.3.3

Product Streams
The product streams may be summarized as under:
Streams
Paraffin Wax
Semi-MCW
Foots Oil

Pressure, Kg/cm2g
O.P.
Mech. Design
4.0
14.0
4.0
14.0
4.0
15.0

Projects & Development India Limited, Sindri

Temperature, oC
Destination
O.P. Mech. Design
80
150
OSBL Storage
80
150
OSBL Storage
45
150
OSBL Storage

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2.3.4

Storage Facilities
The following storage is envisaged within unit battery limit:
Name of Tank

No. x Cap.(m3)

MOC

Design Temp. (oC)

2 x 100
2 x 100
4 x 500
2 x 250
2 x 1500
2 x 1500
1 x 1500
1 x 1500

KCS+1.5 mm CA
KCS+1.5 mm CA
KCS+1.5 mm CA
KCS+1.5 mm CA
KCS+1.5 mm CA
KCS+1.5 mm CA
KCS+1.5 mm CA
KCS+1.5 mm CA

150
65
150
150
150
150
150
150

Slop Tanks
Solvent Tank
Finished Wax Product
Semi MC Wax Product
De-oiled Paraffin Wax
De-oiled Semi MCW
HVGO
MVGO
2.3.5

Utilities

i. Water Requirement
Additional water requirement for the proposed project is estimated about 60 m3/hr. The existing
infrastructure for water supply is adequate to meet the additional requirements.
ii. Cooling Water System
A new Cooling Tower of one cell with circulation rate of 1370 m3/hr has been envisaged for the
proposed project.
iii. Effluent Treatment Plant
The waste water generation from the proposed project is envisaged about 8.1 m3/hr, which
shall be added to the existing Effluent Treatment Plant (ETP) having a capacity of 220 m3/hr.
Present waste water generation from various processes at refinery, is about 110m3/hr.
iv. Satellite Rack Room Building
A new Satellite Rack Room building shall be provided in the west side of De-waxing & Deoiling Unit to house the UPS system for instrumentation requirement.
v. Electrical Sub-Station
A new sub-station shall be provided in the west side of De-waxing & De-oiling Unit.

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vi. Plot Area Requirement
Plot area required for various units/ facilities envisaged for the proposed project is as under:
Name of the Unit
De-waxing & De-oiling Unit
Hydro-finishing Unit
Slabbing & Washing Unit and Warehouse
Satellite Rack Room Building
Sub-Station

:
:
:
:
:

Size of Plot area required

76 M x 135 M
90 M x 60 M
80 M x 40 M
32 M x 18 M
48 M x 30 M

vii. Overall Plot Plan

The overall plot plan of the proposed project may be summarized as under:
The proposed project is envisaged to be located on a plot of about 12.0 hectares area of
land within existing Refinery.
The new facilities proposed under the project have been located keeping in view the
process sequence, safety and operation requirements space available and need for future
expansion.
All the facilities are proposed to be laid out in accordance with safety distance as per
OISD: 118 and Petroleum Rules 2002 of PESO, Nagpur.

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Plate 2.1
Overall Plot Plan

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