PROJECT PRE-FEASIBILITY

REPORT

for

Proposed Expansion Projects

at

Jamnagar Manufacturing Division

V 09/11/2021

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 CONTENTS
C:\Users\Ameya.Kali\Desktop\PFR revised_09112021 R2.docx - _Toc87347472
1. INTRODUCTION ................................................................................................................ 4
1.1. Need for the Proposed Projects. .................................................................................... 5
1.1.1. Multi-Feed Steam Cracker (MFSC) ........................................................................ 6
1.1.2. Multi-zone catalytic cracking (MCC): ...................................................................... 6
1.1.3. C1 (Syngas based) complex................................................................................... 6
1.1.4. C2 complex ............................................................................................................ 6
1.1.5. C3 complex ............................................................................................................ 6
1.1.6. C4 complex ............................................................................................................ 7
1.1.7. Aromatics complex ................................................................................................. 7
1.2. Proposed Land Use ....................................................................................................... 7
1.3. Project Setting ............................................................................................................... 7
1.4. Locational Advantages .................................................................................................. 9
1.5. Proposed Projects ......................................................................................................... 9
1.6. Need for Environmental Clearance: Categorization of the Project ................................. 9
1.7. Capital Cost of the Project ........................................................................................... 10
2. PROJECT DESCRIPTION ............................................................................................... 13
2.1. PetroFCC .................................................................................................................... 13
2.2. MCC / High Severity FCC ............................................................................................ 14
2.3. Multi feed steam cracker (MFSC) ................................................................................ 14
2.4. Aromatics complex ...................................................................................................... 14
2.5. Propane dehydrogenation (PDH)................................................................................. 15
2.6. C1 (Syngas based) chemicals complex........................................................................ 15
2.7. C2 Based Units ............................................................................................................ 16
2.7.1. Chlor alkali ........................................................................................................... 16
2.7.2. Integrated PVC complex (EDC + VCM / PVC) ...................................................... 16
2.7.3. Ethylene Glycol (EG) ............................................................................................ 16
2.7.4. Poly Ethylene (PE) ............................................................................................... 17
2.7.5. POE ..................................................................................................................... 17
2.7.6. Ethylene Propylene Diene Monomer (EPDM) ....................................................... 17
2.7.7. EB / Styrene ......................................................................................................... 17
2.8. C3 Based Units ............................................................................................................ 17
2.8.1. Acrylic acid ........................................................................................................... 17
2.8.2. Glacial acrylic acid................................................................................................ 17
2.8.3. Oxo-alcohols ........................................................................................................ 18
2.8.4. Acrylates .............................................................................................................. 18
2.8.5. Cumene / Phenol.................................................................................................. 18
2.8.6. Isopropyl alcohol .................................................................................................. 19
2.8.7. Propylene Oxide (PO) .......................................................................................... 19
2.8.8. Polyols / Propylene Glycol (PG) ........................................................................... 19
2.8.9. Polypropylene (PP) .............................................................................................. 19
2.8.10. ACN ..................................................................................................................... 20
2.8.11. Epoxy resin .......................................................................................................... 20
2.8.12. Carbon fiber ......................................................................................................... 20
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2.9. C4 Based Units ............................................................................................................ 20
2.9.1. PBR...................................................................................................................... 20
2.9.2. S-SBR .................................................................................................................. 20
2.10. PTA ......................................................................................................................... 21
2.11. Poly-phenylene sulphide .......................................................................................... 21
2.12. Carbon Black ........................................................................................................... 21
2.13. Calcined Petcoke and Graphite grades .................................................................... 21
2.14. Polysilicon / Chloro Silane........................................................................................ 21
2.15. Petcoke gasification ................................................................................................. 21
2.16. Metals recovery and Battery Manufacture ................................................................ 22
2.17. Captive Co-generation Gas/Liquid Based Power Plant ............................................ 22
3.0 ENVIRONMENTAL ASPECTS......................................................................................... 23
3.1 Air Emissions ......................................................................................................... 24
3.2 Water Requirement and Wastewater Generation ........................................................ 24
3.2.1 Water Requirement .............................................................................................. 24
3.2.2 Waste Water Generation ...................................................................................... 24
3.3 Solid / Hazardous Waste Generation ...................................................................... 25
3.4 Biological Environment ............................................................................................ 25
3.5 Socio Economic Environment ...................................................................................... 25

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 Chapter 1
Introduction
1. Introduction
M/s Reliance Industries Limited (RIL) operates an integrated petroleum refinery +
petrochemical complex, referred to as the Jamnagar supersite, which includes
associated utilities, offsites and infrastructure facilities, at Motikhavdi village, in the
Jamnagar district of Gujarat. India.
The Jamnagar supersite represents a prime example of a cluster development,
comprising of the following interlinked clusters:
• DTA or domestic tariff area refinery
• SEZ or special economic zone refinery
• Petrochemical complex
• Gasification complex
• Utilities, offsites and infrastructure facilities
The Jamnagar supersite refines crude oil to produce petroleum products and
petrochemical feedstocks + products.
Utilities for the Jamnagar supersite include seawater intake and outfall facilities,
seawater storage and treatment facilities, integrated desalination and effluent
treatment plants. Utilities also include captive co-generation power plant to supply
100% power and steam to the Jamnagar supersite.
Offsites for the Jamnagar supersite include a marine tank farm to logistically support
crude receipt + product shipping; refinery tank farm to seamlessly support the
supersite operations; and rail/road tank farm + warehouses to support efficient
storage + dispatch of refinery products.
The infrastructure facilities, to support the Jamnagar supersite, include deep water
Single Point Moorings (SPMs) for the receipt of crude oil + export of petroleum
products and associated pipelines; liquid jetties + shipping berths, and associated
pipelines + approaches to the jetties for dispatch of products; RO-RO jetty + LO-LO

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 jetty for handling project cargoes; on-shore terminals for storage of crude + products
and rail + road loading and unloading bays.
Jamnagar is connected to the cross-country pipelines for inland LPG distribution +
regasified LNG receipt.
The existing Environmental Clearance (EC) for the crude refining capacity of the
Jamnagar supersite is 68.2 Million Tons Per Annum (MMTPA).
The Jamnagar refinery, started operations at 18 MMTPA, in 1999. The existing
refining capacity was enhanced to 33 MMTPA, via debottlenecking + value / product
maximization, plus a new 26.7 MMTPA refinery capacity added, subsequent to
obtaining the environmental clearance from the Ministry of Environment and Forest
(MoEF), for 59.7 MMTPA, in 2005. Further expansion to 68.2 MMTPA was
operationalized, in 2011, after obtaining Environmental Clearance from MoEF, in
2010.
The Jamnagar supersite is a global refinery icon, because:
• Largest refinery, at a single location
• Largest refinery off-gas cracker, for deep refinery-petrochemical integration
• Largest petcoke gasification, for a “bottom-less” refinery
• High complexity, for maximum crude-to-product flexibility
• High energy efficiency, for low ecological footprint
• Advanced automation, for effective monitoring, control and optimization
The Jamnagar supersite represents the pride of a resurgent India.
Aligned to the national “Make-in-India” objective, RIL plans to optimally leverage the
Jamnagar refinery + gasification assets, as a future growth platform, to maximize
petrochemicals, termed as “crude-to-chemicals”.

1.1. Need for the Proposed Projects.

The proposed Jamnagar growth projects shall boost India’s development and
prosperity objectives. Following strategies have been adopted for RIL’s future
projects in Jamnagar.
• Upgrade advantage Jamnagar feeds, via molecule management, to value-added
petrochemicals and thereby reduce India’s high chemical imports.
• Employ disruptive technology innovation to minimize the cost of chemicals to
ensure global competitiveness
• Supply competitive chemicals for labour-intensive secondary and tertiary
processing sectors to boost India’s employment potential
• Usher in future-forward digitalization technology for “Smart Manufacturing”
• Leverage existing assets to cost-efficiently transform Jamnagar for crude-to-
chemical
• Ensure responsible, circular use of chemicals to eliminate the scourge of plastic
waste
The proposed crude-to-chemical mission shall leverage following advantage feeds
for competitive chemicals:
• Reroute petcoke gasification derived syngas + CO from fuel to C1 chemicals
• Upgrade refinery streams, to olefins-based C2 + C3 chemicals.
• Value add C6 - C11 streams to aromatics-based chemicals
• Ultimate goal is to maximize value

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1.1.1. Multi-Feed Steam Cracker (MFSC)
Maximize chemical monomers, by upgrading refinery’s saturated light streams, priced
lower than crude, via stream cracking, in a MFSC.
1.1.2. Multi-zone catalytic cracking (MCC):
Further, maximize chemical monomers, by upgrading refinery unsaturated light
streams + heavy streams, via catalytic cracking. MCC represents the ultimate in
catalytic cracking conversion + severity, termed as an ultra-severity FCC.
The existing FCCs at Jamnagar shall be sequentially converted to high severity FCC
or Petro FCC. Petro FCC maximizes olefins + aromatics instead of gasoline.
The Jamnagar crude-to-chemical transformation is accomplished by an optimal
combination of MFSC + PetroFCC conversion + MCC
1.1.3. C1 (Syngas based) complex
The petcoke gasification generates carbon-rich syngas, an excellent feedstock for
carbon-rich syngas based chemicals. The Jamnagar growth projects propose to
leverage this CO-rich syngas, as a fountainhead for a world-scale + world-class C1
complex, comprising of the following indispensable syngas based chemicals:
• Acetic acid and Acetic anhydride
• Acetic acid derivatives of ethyl acetate + VAM, or vinyl acetate monomer
• VAM derivatives of VAE or vinyl acetate ethylene + EVA or ethylene vinyl acetate
• Methanol, formic acid and DME, or di-methyl ether

DME is especially versatile, as both fuel + petrochemical feedstock. The Jamnagar

DME shall be shipped to other RIL sites, to convert to olefins.
1.1.4. C2 complex
Ethylene shall be sourced primarily from the MFSC + MCC + ROG Cracker
debottlenecking.
Petro FCC conversion increases C2 content in the refinery off-gas, requiring a ROG
Cracker debottlenecking for additional ethane-to-ethylene.
This ethylene shall be the building block for the following C2 chemicals:
• Poly ethylene
• Ethylene oxide + MEG or mono ethylene glycol
• Ethylene oxide derivatives of DEG and TEG
• EDC + VCM + PVC for the vinyl chain

These C2 chemicals are vital because MEG a fibre intermediate, can clothe India and
PVC, used for pipes, can support India’s agriculture + housing sectors.
1.1.5. C3 complex
Propylene shall be sourced primarily from the MCC + MFSC.
This propylene shall be the building block for the following C3 chemicals:
• Poly propylene
• Acrylic acid
• Acrylic acid derivatives of acrylates + SAP
• Oxo alcohols
• Cumene + phenol/acetone
• Acetone derivative of iso-propyl alcohol
• Phenol derivative of polycarbonate, via non-phosgene, safe processing
• PO or propylene oxide
• PO derivative of polyols
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 • POE or Polyolefin elastomers
• Epoxy resins for carbon fibre
• ACN or acrylonitrile for carbon fibre
Acrylic chemicals support paints for housing and hygiene products. Phenolic
chemicals support engineering plastics to light-weight transport. Polyols
support polyurethanes a wonder plastic with diversified uses. Acrylonitrile
support carbon fibre for high performance uses.
1.1.6. C4 complex
Butadiene shall be generated as a co-product from MFSC, supplemented by
on-purpose dehydrogenation of butenes.
The Jamnagar butadiene shall be shipped to other Reliance sites, to feed SBR
or styrene butadiene rubber + PBR or poly butadiene rubber.
1.1.7. Aromatics complex
Benzene, an exportable Jamnagar surplus, shall be supplemented by MFSC
+ MCC, via BTX extraction.
Refinery C7 shall be upgraded to maximum toluene, in a high-severity catalytic
reformer.
Toluene, sourced from BTX extraction + high-severity catalytic reformer, shall
be converted to additional xylenes via new toluene methylation +
debottlenecking alkylation.
Mixed xylenes, sourced from BTX extraction + toluene methylation +
transalkylation shall maximize PX, via PX recovery.
The Jamnagar PX shall be shipped to other RIL sites also, to feed PTA +
polyester for labour - intensive textile sector.
1.2. Proposed Land Use
For setting up the crude-to-chemical growth projects in Jamnagar, RIL proposes to
develop a total area of 2000 acres adjacent to the existing Jamnagar supersite.
The plot plan indicating the location of the proposed projects are enclosed as Figure
1.1.
1.3. Project Setting
Jamnagar district lies in the peninsular region of North West, India, in the state of
Gujarat, known as Saurashtra. The Jamnagar district boundary to the north is the Gulf
of Kutch, to the East by Rajkot district, to the South by Junagadh district and to the
West by Devbhoomi Dwarka District and the Arabian Sea.
The Jamnagar region falls in an arid zone. The area is covered by Deccan trap basalt
of cretaceous age. Existing land use is mainly scrub land (wasteland), followed by
fallow land. The site has been selected for the development of proposed projects
because it does not compete with agriculture or farming.
Recent, industrial development by public sector undertakings, private sector
organizations and port development has ushered in a recognizable economic boom,
leading to all-round prosperity + higher standard of living in Jamnagar + surrounding
areas.
The latitude and longitude of the center of the proposed complex is 22o20.115’N and
69o53.247’ E.
Jamnagar is a recognized centre for the Brass industry + Bandhani fabrics (tie-&-dye
work on fabrics) + Zari sarees + Silk & Gold embroidery. Other major manufacturing
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sites in the adjoining area include Thermal Power Plant of the Gujarat Electricity
Board, Cement manufacturing unit of Digvijay Cements, Refinery of Nayara, earlier
Essar, and a Fertilizer unit of the Gujarat State Fertilizer Corporation.
Other industries, including agro & food processing, biotechnology, chemicals & allied
industry, drugs & pharmaceuticals, gems & jewelry, engineering including automotive,
are also located in the Jamnagar district of Gujarat.
The existing industrial estates by GIDC around the Jamnagar site include:
• Shankar Tekri industrial estate, Jamnagar1
• Kamsudra industrial estate, Jamnagar 2
• Dared industrial estate, Jamnagar 3
• Jam Khambhaliya industrial estate
• Bhatia (RIDC)
The following siting criteria, delineated by MoEF&CC, New Delhi has been strictly
followed by RIL, for locating the proposed projects:
• The project will be located on barren land and the proposed expansion shall be
within the land belonging to RIL.
• The land proposed for expansion is a barren arid land and has sufficient space
to provide for a green belt.
• Layout and form of the project will conform to the landscape, without affecting
any geographical features.
• The scenic beauty of the area shall increase with the green belt around
proposed growth projects.
• Associated township for the proposed growth project can be developed taking
into account the predominant + prevailing wind direction.
• The proposed growth projects will not fall within the prohibited CRZ area or the
forest area.
In addition to the siting criteria listed above, the proposed project location has been
reviewed for the following salient features:
• Although the site is not prone to natural disasters, the proposed growth projects
shall be designed to the seismic codes specified by ISI and allied agencies. It is
pertinent to note that Gujarat Earthquake of 2002 with epicenter near Bhuj, did
not adversely impact the integrity of the Jamnagar Refinery.
• Water for operation will be made available from the proposed desalination plant.
• Roads with adequate width and capacity are available to handle the increase in
traffic load.
• Construction materials will be principally sourced from local & neighboring area
to avoid long distance transportation. Stone chips and aggregates for
construction will be sourced from govt. approved vendors / quarries.

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1.4. Locational Advantages
The principal drivers for the proposed growth projects in Jamnagar are:
• Maximize value addition of crude refined.
• Minimize the cost of production, with process integration + technology
innovation.
• Exploit economies of scale to ensure capex competitiveness.
• Ensure sustainability, with bespoke application + circularity adoption.
• Leverage world class infrastructure and logistics facilities at Jamnagar to ensure
global competitiveness.
Proposed growth projects in Jamnagar leverages the following strengths.
• RIL has a successful track record in executing mega + technically complex
projects, upholding the highest standards of health, safety and environmental
protection.
• An enviable project implementation record of high quality + low capex +
accelerated schedule
• The material supply, in the form of polymers + polyesters, shall spawn ancillary
and derivative industries, with high employment + import substitution potentials.
• Jamnagar is ideally located in western India, having the highest chemical/
polymer consumption + established secondary processing platform for easy
product absorption.
• Access to the deep draft port facilities shall streamline machinery intake +
product offtake.
• The proposed project location meets the following siting criteria/guidelines of
the MoEF:
➢ Located away from the CRZ areas
➢ Barren land
• The proposed project location is well connected with the national and state
highways.
1.5. Proposed Projects
The details of the proposed projects are given in Table 1.1. In addition to the projects
listed in Table 1.1 the infrastructure for storage and dispatch of the products will also
be established. This will include facilities for road and rail transportation, modification
of the existing marine facilities for solid handling etc. The residential township will also
be expanded for accommodating additional personnel / employees required for
construction as well as O & M of the projects.
1.6. Need for Environmental Clearance: Categorization of the Project
The company needs to obtain the Environmental Clearance prior to construction of the
proposed expansion projects as per the EIA Notification of 14th September 2006
including its amendments. The proposed projects, as per the Schedule of the EIA
Notification 2006, may be categorised to be covered by 1 (d) Thermal Power Plant, 3
(a) Metallurgical Industries, 4 (a) Petroleum Refining, 4 (d) Chlor-Alkali, 5(a) Fertilizers
and 5(c) Petrochemical Complexes.
The water requirement for the projects will be met by desalination and the return sea
water discharge from the desalination plant will require CRZ clearance for discharge as
it will be in CRZ IV region.

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 1.7. Capital Cost of the Project
The overall capital cost of the proposed project will be Rs. 70,000 Crores.
Table 1.1 - Details of the proposed unit capacities at JMD
Growth Projects
Sr. Projects Capacity Feedstock Remarks
(kTA) Feed stock
A Building blocks
Conversion of FCCs
1 High severity FCCs Existing Petro FCC conversion
to Petro FCC
8500 C2= + C3=, Heavy VGO / New complex includes
2 MCC / HSFCC complex 4000 Xylenes and HCGO + Light product recovery and
1600 Benzene ends Aromatic section
New and debottlenecking of
Multi-Feed Steam PCN / Offgases
3 6520 C2= + C3= existing ROGC includes BD
Cracker (MFSC) complex / C3s / C4s
extraction
Naphtha /
4 Aromatic complex 1300 PX Including new Reformer
Methanol
5 PDH 1500 C3= C3 Propane dehydrogenation

B C1 Chemicals

6.1 Acetic Acid (AA) 3000 CO / Methanol

6.2 Acetic Anhydride 750 AA AA derivative

6.3 Ethyl Acetate 1500 AA / Ethanol AA derivative

6.4 VAM 1050 AA / C2= AA derivative

6.5 VAE 900 VAM / C2= VAM derivative

6.6 Poly Vinyl Acetate (PVAc) 300 VAM VAM derivative

6.7 Poly Vinyl Alcohol (PVAL) 150 PVAc PVAc derivative

6.8 Formic Acid 400 CO Syngas derivative

6.9 DME 2700 Syngas Methanol substitute

6.10 Polyketone 350 CO / C2= Syngas derivative

6.11 Iso-Nonyl Alcohol (INA) 300 CO / C4= Syngas derivative

6.12 MMA 700 CO / C2= / C4= Syngas derivative

6.13 PMMA 350 MMA MMA derivative

Air Separation
6.14 Rare Gases 50 Kr + Ne + Ar
Unit
Air Separation
6.15 Oxygen / Nitrogen 360
Unit
6.16 Methanol 3600 Syngas Syngas derivative

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 B C1 Chemicals

6.17 Ethanol 500 Syngas Syngas derivative

H2 / Syngas /
6.18 NH3 6000 Incl. waste water recovery
N2
6.19 Urea 3900 NH3 / CO2 NH3 derivative

C C2 Chemicals

7.1 Chlor / Alkali 3000 / 3500 Salt Chlorine / caustic

7.2 EDC / VCM+PVC 3780 / 4500 C2= / Chlorine Integrated PVC complex

7.3 MEG / DEG 4500 C2= / Oxygen

7.4 PE 2000 C2= Multi-grade

7.5 POE 500 C2= / Octene-1 Solar cell applications

7.6 EPDM 240 C2= + C3= Elastomer

7.7 EVA 450 C2= / VAM

7.8 EB / Styrene / PS 1000 C2= / Benzene

D C3 Chemicals

8.1 Acrylic Acid 720 C3=

8.2 Glacial Acrylic Acid 150 Acrylic Acid Acrylic Acid derivative

8.3 Oxo-Alcohols 740 C3=

8.4 Acrylates 800 Acrylic Acid Acrylic Acid derivative

8.5 Cumene 1500 C3= / Benzene Phenol intermediate

8.6 Phenol 1000 Cumene

8.7 Acetone 620 Cumene Phenol by product

Phenol /
8.8 Bisphenol-A (BPA) 500 Phenol derivative
Acetone
8.9 Polycarbonate 600 BPA / EO Phenol derivative

8.10 Iso-Propyl Alcohol 250 Acetone Acetone derivative

8.11 Propylene Oxide (PO) 1000 C3=

Polyols/Propylene Glycol
8.12 800 PO PO derivative
(PG)
8.13 Polypropylene 5200 C3=

8.14 Acrylonitrile (ACN) 600 C3= / Ammonia Carbon fibre precursor

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 D C3 Chemicals

8.15 Epoxy resin 250 BPA / ECH Carbon fibre precursor

8.16 Carbon Fibre 300 ACN H2 storage applications

E C4 Chemicals

9.1 PBR 280 BD BD derivative

9.2 S-SBR 650 BD / styrene BD derivative

F Heavies/Others

10 PTA 3500 PX

11 Polyphenelyne sulphide 315 Bz / Sulphur

12 Carbon Black 600 CBFS / FO

Calcined Petcoke and
13 500 CSO
Graphite grades
14 Polysilicon / Chloro Silane 90 Silicon/chlorine For PV applications
Coke/coal
15 Petcoke gasification 2250 Refinery / Debottlenecking
Import
Metals recovery and
16 35 Petcoke cinder Gasification
Battery Manufacture
Gas / Liquid
17 Power (MW) 3000 O2C + Giga factories
(Refinery)

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 Chapter 2

Project Description
2. Project Description
Introduction
The Jamnagar Refinery complex comprises of 2 existing side-by-side refineries –
Domestic Tariff Area (DTA) and Special Economic Zone (SEZ), at Jamnagar, Gujarat.
The Jamnagar refinery complex has processed 150+ crude grades, which represents
almost half of crudes grades traded globally. The Jamnagar refinery complex primarily
produces transportation fuels and petrochemical products. Approx. 60% of products
from the Jamnagar refinery complex are exported. The Jamnagar refinery complex is
integrated with petrochemicals, utilities & power and ports & terminal facilities. Self-
sufficiency in utilities and power is achieved, by sea water desalination, captive power
plant and recycle & reuse of water. Technology is licensed from global licensing
leaders for the Jamnagar refinery complex.
2.1. PetroFCC
Existing FCCs in the Jamnagar refinery complex maximizes yields of gasoline
followed by propylene + ethylene. Increasing the operating severity, these FCCs can

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 be converted to PetroFCC, which maximizes yields of propylene + ethylene followed
by gasoline. PetroFCC enables the Jamnagar transformation for oil-to-chemicals.
The FCCs will be retrofitted with Flue Gas Desulphurization units for control of SO 2
emissions. The FGD units will involve scrubbing of SO2 from flue gasses. The
resultant scrubbing solution of NaOH / Lime will be further oxidized by aeration. The
solids will be settled and disposed as waste and the supernatant will be routed
through the existing ETP.
2.2. MCC / High Severity FCC
Multi-zone catalytic cracking (MCC) an ultra-severity FCC or high severity FCC
(HSFCC) with customized catalyst, beyond the high severity PetroFCC. MCC /
HSFCC employs a FCC type reactor – regenerator platform. The different zones of
MCC are optimized for the feed cracking propensity, with different cracking severity
+ residence time, to maximize ethylene + propylene yields from a range of feeds. A
cracking furnace cracks light molecules (C2 and C3) into olefins.
In addition, it will have following sections:
• C2= + C3= recovery
The cracked light hydrocarbons are compressed, dried and ethylene + propylene
is recovered.
• BTX+ extraction
BTX+ recovery technology uses extractive distillation to remove benzene,
toluene, xylene and A9–A11 aromatics (BTX+) from refinery, aromatics streams
• Toluene methylation
Toluene methylation is an effective and economical solution to maximize the PX
yields by adding the methyl group from low-cost methanol or DME to the aromatic
ring.
• Trans-alkylation
Trans-alkylation process produces benzene and xylenes through transalkylation
of the methyl groups from toluene and/or heavy aromatics streams.
2.3. Multi feed steam cracker (MFSC)
MFSC can crack naphtha minus light streams into ethylene + propylene + butadiene
+ BTX or petrochemical building blocks.
The additional Propane feed available at Jamnagar, will help to debottleneck this
ROG Cracker for additional olefins.
Additionally, a new MFSC is also planned. The hot section of the cracker consists of
pyrolysis furnaces that crack the feedstock into ethylene, propylene and other light
hydrocarbons.
The new MFSC comprises of the following constituent sections.
• C2= + C3= recovery
The cracked light hydrocarbons are compressed, dried and ethylene + propylene
is recovered.
• Butadiene extraction
Butadiene extraction uses N-methylpyrrolidone (NMP) as a selective solvent to
recover 1,3-butadiene from a crude C4 mix
2.4. Aromatics complex
The Aromatics Complex comprises of Xylene Fractionation, Crystallization or
Selective Adsorption and Isomers units. PX is recovered from mixed xylenes,
because of differences in either crystallization or adsorption, leading to PX, with a
purity of 99.8 wt%, and recovery of 94-97 wt% of PX in a single pass.
High Severity Reformer

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 High severity reformer is used to maximize the naphtha conversion to Aromatics-rich
reformate, a feed source for PX recovery. High severity reformer adds a
supplementary stand-alone reactor to the standard, moving bed, 3 reactor
configuration to maximize C7 conversion to toluene. The reactors are integrated with
fired heaters to support the endothermic reforming or crystallization process to
aromatics. The reactors are supported by continuous catalyst regeneration. The
catalyst contains Platinum, noble metal. The reforming reaction is driven by high
temperature and low pressure, just above atmospheric.
2.5. Propane dehydrogenation (PDH)
Propane, sourced from the refinery complex can be dehydrogenated to
propylene. Process is catalytic dehydrogenation of propane to propylene. The
unconverted propane is recycled back with the fresh propane.
There are 3 reactor options for the highly endothermic PDH reactions:
• Fixed bed, swing reactor, with heat generating matter
• Moving bed reactor, with continuous catalyst regeneration
• Fluidized bed reactor- regenerator, similar to a FCC
The propylene-rich reactor effluent is compressed, dried and sent to a cryogenic
separator where hydrogen is recovered. The olefin product is then sent to a selective
hydrogenation process where dienes and acetylenes are saturated to mono-olefins.
2.6. C1 (Syngas based) chemicals complex
C1 complex will comprise of chemicals based either on carbon-rich syngas or carbon
monoxide.
Acetic acid is produced from carbon-rich syngas and further converted to downstream
chemicals like acetic anhydride, ethyl acetate and vinyl acetate monomer (VAM).
VAM is polymerized to polyvinyl acetate by emulsion polymerization and further to
polyvinyl alcohol by hydrolysis of polyvinyl acetate. VAM is also used to manufacture
downstream polymers such as Vinyl acetate ethylene emulsions (VAE) and Ethylene
Vinyl Acetate copolymer (EVA) by copolymerization of VAM and ethylene.
C1 complex will also include production of methanol, formic acid, di-methyl ether
(DME) and Poly-ketone. Methanol will be produced from Synthesis gas, a mixture of
hydrogen, carbon oxides, and methane under high pressure operations. Methanol
and carbon monoxide react to form methyl formate, which is hydrolyzed to produce
Formic acid. Syngas-to-DME shall be a 1-step process, employing novel, high stability
catalyst. Poly-ketones are semi-crystalline thermoplastics formed by the
copolymerization of CO with ethylene.
Ethanol is synthesized via bio-fermentation of waste gases from petcoke gasification
and H2 recovery. CO is the preferred feed, while pure CO2 can be added to saturate
the carbon requirements for the microbes.
INA is obtained by hydroformylation of octane with syngas, to the corresponding C9
aldehydes and the subsequent hydrogenation thereof.
Methyl methacrylate (MMA) is produced using methanol, carbon monoxide and
ethylene. It is further polymerized to get polymethyl methacrylate (PMMA).
Ammonia is recovered from sour water of refining + gasification process by passing
through a de-gasser and de-oiler, where light hydrocarbons and other dissolved
gases are removed. In addition, Ammonia is also produced by reacting hydrogen from
syngas with nitrogen from air separation units.
Compressed CO2 and ammonia are mixed in the urea reactor to form urea. Weak
urea solution generated is concentrated in multiple stages. Final urea concentration
is done in evaporators.

15
 The six naturally occurring noble gases are helium, Neon, Argon, Krypton and Xenon
and the radioactive Radon. Neon, Argon and Krypton are obtained from air in an air
separation unit (ASU) by liquefaction of gases and fractional distillation. Similarly,
Oxygen and Nitrogen are also recovered from ASU by fractional distillation.
2.7. C2 Based Units
2.7.1. Chlor alkali
Chlorine is obtained from chlor alkali unit which electrolyzes salt to make caustic.
Chlorine is used for producing EDC.
2.7.2. Integrated PVC complex (EDC + VCM / PVC)
Ethylene-di-chloride (EDC) is produced from ethylene and chlorine. Vinyl chloride
monomer (VCM) is produced from EDC and ethylene. The reaction is exothermic and
highly selective to VCM, resulting in high yields + product purity.
Poly Vinyl Chloride (PVC) is produced by the suspension polymerization of VCM or
vinyl chloride monomer. VCM and water are introduced into the reactor along with a
polymerization initiator viz. dioctanoyl peroxide and/or dicetyl peroxydicarbonate. The
contents of the reaction vessel are continuously mixed to maintain the suspension
and ensure a uniform particle size of the PVC resin. The reaction is exothermic and
requires cooling. PVC is denser than VCM hence the volume is reduced during the
reaction, and hence water is continuously added to the mixture to maintain the
suspension. The average molecular weights range from 45,000 to 64,000. PVC slurry
is degassed and stripped to remove excess VCM, which is recycled. The polymer is
then passed through a centrifuge to remove water. The slurry is further dried in a hot
air bed, and the resulting powder is sieved before storage or pelletization.
2.7.3. Ethylene Glycol (EG)
Principal EG products are mono ethylene glycol (MEG) and di ethylene glycol (DEG).
Ethylene glycol is produced from ethylene in a 2-step process via ethylene oxide (EO)
as an intermediate.
The MEG is produced by first converting ethylene-to-ethylene oxide (EO) through a
direct oxidation process and then hydrolyzing the same.
Ethylene, recycle gas and oxygen are thoroughly mixed, preheated and passed
through the EO reactor, where ethylene is converted into EO at elevated temperature
and pressure. The reaction product gas is scrubbed with neutralizing liquid to remove
acidic compounds and further cooled in EO absorber by counter contact with water,
which absorbs EO and forms a dilute aqueous solution. The gas after scrubbing and
absorption of EO is recycled back to the reactor via a recycle gas compressor. A small
slip stream is taken to CO2 removal section for removal of CO2 formed in the reactor,
by absorption in hot potassium carbonate solution. Dilute aqueous solution of EO in
water is stripped off. EO from stripper are cooled, condensed and purified by passing
through light ends columns, which removes lighter fractions. Purified EO mixture is
heated, mixed with additional water and passed through tubular glycol reactor. The
reaction takes place in liquid phase under elevated temperatures and pressure. The
conversion is almost complete and the glycol water mixture is sent for evaporation.
In evaporation section, water is separated from glycol mixture in a triple effect
evaporator with subsequent vacuum column.
Crude glycol mixture is separated into MEG, Diethylene Glycol (DEG) and Tri-
ethylene Glycol (TEG).

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2.7.4. Poly Ethylene (PE)
Principal polymers of ethylene, or polyethylene, can be high density PE (HDPE), low
density PE (LDPE) and linear low density PE (LLDPE). The process involves
converting gaseous ethylene into solid phase PE by solution polymerization process,
using cyclo-hexanes as the solvent.
A purified solution of ethylene, solvent and co-monomer (octene or butene or both) is
fed to the reactor. Co-monomer is added for low-density PEs. Catalyst helps to
polymerise the ethylene and co-monomer. A chain terminator agent is used to control
molecular weight (polymer chain length).
About 95% of the ethylene is converted to PE on each pass. The molten polymer
solution flows to the extruder which feeds an underwater pelletizer. The pellets
formed are water conveyed to a continuous stripper to remove residual solvent, which
is condensed and recovered. The stripped PE pellets are dried and fed to pneumatic
blenders for blending into uniform lots.
2.7.5. POE
POE or poly-olefin elastomer is a copolymer of ethylene and octene or ethylene and
butane produced using catalytic process
2.7.6. Ethylene Propylene Diene Monomer (EPDM)
This process involves solution polymerization of monomers; ethylene, propylene and
diene in the presence of Ziegler Natta catalysts. The solution polymerization process
is the most widely used and is highly versatile for making a wide range of EPDM
Rubber grades. Ethylene, propylene and dienes are polymerized in the presence of
catalyst systems in an excess of hydrocarbon solvent. Stabilizers and oils, if used,
are added directly after polymerization. The polymer, which is in crumb form, is dried
with dewatering screens, mechanical presses and then by drying ovens. The crumb
is formed into wrapped bales or extruded into pellets. The high viscosity crystalline
polymers are sold in loosely compacted, friable bales or as pellets. The amorphous
polymer grades are typically packed in solid bales.
2.7.7. EB / Styrene
Benzene and ethylene are fed to the zeolitic, liquid phase reactor. Ethylene feed
reacts completely, leaving only inert constituents. Poly ethyl benzene that is produced
by successive alkylation is transalkylated with benzene to produce ethyl benzene
(EB).
The EB is then catalytically dehydrogenated to styrene in the presence of steam.
2.8. C3 Based Units
2.8.1. Acrylic acid
The propylene is oxidised with compressed air, and is converted into Acrolein and
further the Acrolein is oxidized to Acrylic Acid. The effluent gas containing Acrylic
Acid is quenched and absorbed with the descending water and the aqueous solution
of acrylic acid is obtained. Part of the off gas with non-condensables such as acrolein,
acetaldehyde, propane and unreacted propylene is recycled to the oxidation reactor.
Water and acetic acid are eliminated by azeotropic distillation. Ester grade acrylic
acid is obtained from the top, while the bottom contains acrylic dimer and other heavy
ends. Aldehydes and ketones contained in the crude acrylic acid react with the
hydrazine hydrate forming hydrazone compounds. These are separated by
distillation in the High Purity Acrylic Acid (HPAA) distillation column.
2.8.2. Glacial acrylic acid
The acrylic acid monomer solution is purified to produce glacial acrylic acid which can
be polymerized to produce super absorbent polymer or SAP
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2.8.3. Oxo-alcohols
2.8.3.1. n-Butanol
Syngas and propylene are fed to a primary hydroformylation reactor, over aqueous
catalyst solution of Rhodium complex. The effluent then passes to decanter to
separate the aqueous from the organic phase and to degas any entrained gases. The
product is then passed through a decanter to remove remaining aqueous catalyst
solution, prior to purification. The liquid effluent is distilled to separate the aldehyde
products from the catalyst and the high-boiling byproducts. The crude butyraldehyde
product from the secondary reactor system is combined with the product from the
primary reactor system for purification.
Butyraldehyde is fed to cross-countercurrent heat exchanger where it is mixed with
recycle H2 gas for hydrogenation to produce n-butanol.
2.8.3.2. 2-Ethyl Hexanol
2-Ethyl Hexanol is also produced by catalytic hydroformylation of propylene with
syngas, using rhodium catalysts. Since, the reactor effluent contains butanol and
water impurities, the crude 2-ethyl hexanol product is purified by fractionation.
2.8.4. Acrylates
n-Butylacrylate is produced by esterification of acrylic acid in presence of acid
catalyst. Acrylic acid and n-butanol in an equi-molar ratio are fed continuously to an
agitated reactor in presence of acid based catalyst and polymerizing agents. The
reactor is maintained at high temperature for faster reaction.
Ethyl acrylate is produced by substituting n-butanol with ethanol. Methyl acrylate is
produced by substituting alcohol with methanol. 2-ethyl hexyl acrylate is produced by
substituting alcohol with 2-ethyl hexanol.
2.8.5. Cumene / Phenol
The Cumene process primarily consists of following sections:
• Alkylation: Alkylation of Benzene by propylene
• Benzene recovery: The benzene column recovers excess benzene from the
alkylation and transalkylation reactor effluents for recycle to the reactors, removes
the nonaromatic components which are contained in the benzene feedstock, and
dries the fresh benzene being fed to the unit.
• Cumene Column: The bottoms from the benzene column is fed to the cumene
column. This column separates the final cumene product from PIPB and heavies.
The column is reboiled by high pressure steam, and low pressure steam is
generated in the condenser. Cumene product is recovered as a distillate and the
bottoms are pumped to the PIPB column.
• PIPB Column: The PIPB column recovers DIPB and most of the TIPB from the
cumene column bottoms for recycle to the transalkylation reactor. PIPB is
recovered as a side stream from this column, and fed to the transalkylation reactor
for conversion to cumene.
• Transalkylation: The DIPB product from the PIPB column is mixed with benzene,
and fed to the transalkylation reactor. DIPB and TIPB are partially converted to
cumene with benzene. The effluent from the transalkylator flows to the benzene
column for removal of the excess benzene and the subsequent recovery of
cumene and PIPB.
Phenol and acetone are jointly produced from cumene by liquid phase oxidation of
cumene to cumenehydroperoxide (CHP) followed by catalytic de-composition of CHP
to phenol and acetone.
Isopropyl alcohol (IPA) is manufactured by indirect hydration of propylene, called the
sulphuric-acid process.
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2.8.5.1. Bis phenol A (BPA)
BPA is produced by the condensation of phenol and acetone in the presence of an
acid catalyst typically hydrochloric acid and methyl mercaptan as promoter. Acid and
phenol are recovered from the reactor effluents. The BPA is washed with water,
neutralised with calcium hydroxide and distilled under vacuum to purify the BPA.
2.8.5.2. Polycarbonate
Polycarbonate is produced by trans-esterification of di phenyl carbonate (DPC) with
BPA in two stages. The process is commonly known as melt process having
advantage of producing polycarbonate in undiluted form which can be directly
palletised.
DPC is produced by using an intermediate di-alkyl carbonate, usually dimethyl
carbonate (DMC), as the source of carbonate functionality. In first step phenol is
reacted with dimethyl carbonate to make phenyl methyl carbonate. In second step
phenyl methyl carbonate is reacted with phenol to convert to DPC.
BPA and DPC are reacted and phenol is removed to produce a pre-polymer of
Polycarbonate. Polymerisation to a higher molecular weight polycarbonate occurs
primarily through an ester disproportionation whereby DPC is formed and recycled.
2.8.6. Isopropyl alcohol
IPA can be manufactured by indirect hydration of propylene, called the sulphuric-acid
process. In the indirect-hydration process, propylene is reacted with sulphuric acid to
produce mono- and di-isopropyl sulfates, which are then hydrolysed to isopropanol.
2.8.7. Propylene Oxide (PO)
The unit consists of three process sections:
• Reduction and oxidation of a working solution
• Recovery and purification of hydrogen peroxide solution
• Working solution regeneration.
The working solution selected is a mixture of ethylanthraquinone (EAQ),
tetrahydroethylanthraquinone (THEAQ), its corresponding hydroquinone (THEAHQ),
and inert compounds in a mixed solvent of 21.4-wt% triethylhexyl phosphate and
76.6-wt% aromatic solvent (mixed alkylbenzenes). The purified product is a 37-wt%
hydrogen peroxide solution. The propylene and hydrogen peroxide solution flow
counter-currently in the epoxidation reactors. The bottom stream from reactor is fed
into crude PO column. Crude PO stream is recovered as overhead and is sent to the
PO purification section for further purification to recover PO with 99.98% purity. The
TBA/water solvent is recycled after the removal of methanol in column.
2.8.8. Polyols / Propylene Glycol (PG)
Catalytic polymerization of PO result in the production of polyols.
Propylene Glycol is produced by high pressure, high temperature, noncatalytic
hydrolysis of Propylene Oxide. A large excess of water is used in the conversion
of Propylene Oxide to a mixture of Mono-, Di-, and Tripropylene Glycols. This
increases the selectivity of desired Mono-product. Water is recycled. Typical product
distribution is 90% Propylene Glycol and 10% coproducts.
2.8.9. Polypropylene (PP)
PP can be in 3 product forms, termed as either homopolymer or random copolymer
or impact copolymer.
Propylene polymerisation to PP, in presence of hydrogen and catalyst, in a fluidized
bed reactor form homopolymer resin.

19
 Polymerisation of ethylene and propylene to PP in presence of hydrogen and catalyst
in a fluidized bed reactor form random copolymer resin.
Homopolymer PP reacted further, with ethylene, propylene and hydrogen in a second
reactor form impact copolymer resin.
Only one type of resin can be produced per line in a batch mode. The resin is then
sent to resin degassing and unreacted monomers are sent to vent recovery and are
recycled back to reactors after separation.
Wet degassed resin is sent to finishing section, wherein additives are added to
stabilize the resin, and extrude it to pellets of uniform size.
2.8.10. ACN
Acrylonitrile is manufactured by combining propylene, ammonia, and air in a process
called ammoxidation.
2.8.11. Epoxy resin
Epoxy resin is produced using bisphenol-A and epichlorohydrin. It is a pre-cursor for
production of carbon fiber
2.8.12. Carbon fiber
Carbon fiber is produced using acrylonitrile and epoxy resin. The process for making
carbon fibers is part chemical and part mechanical. The precursor is drawn into long
strands or fibers and then heated to a very high temperature without allowing it to
come in contact with oxygen. Without oxygen, the fiber cannot burn. Instead, the high
temperature causes the atoms in the fiber to vibrate violently until most of the non-
carbon atoms are expelled. This process is called carbonization and leaves a fiber
composed of long, tightly interlocked chains of carbon atoms with only a few non-
carbon atoms remaining.
2.9. C4 Based Units
2.9.1. PBR
First step is purification of solvent and monomers through distillation operations, and
catalyst preparation. It is fed to the first reactor of the polymerization train. The dry
mix feed (butadiene and hexane) coming from the purification systems is fed to the
reactor together with the catalyst solution. Butadiene polymerization takes place in
continuous stirred reactors operating in series.
The polymer solution leaving the reactors is mixed with the stopping agent to destroy
the catalyst and then is discharged into blend tanks in order to homogenize the
product. Vapour coming from blend tanks are condensed and sent to column to
separate and recycle the non-reacted monomer. The blended solution with the
antioxidant agents is fed to the stripping section where the solvent is removed by
steam distillation in the presence of a dispersing agent aimed to control the crumb
size in the slurry.
The crumb slurry is then pumped to the finishing unit, where the crumb is dewatered
on a shaker screen, being the water partly re-circulated to the strippers and partly
sent to waste water treatment. The vapours obtained from the stripping section are
otherwise condensed and the solvent, separated from water by a decanter, is sent to
the wet solvent tank. The dewatered crumbs are dried in two mechanical extruders in
series, cooled with air, weighed and baled.
2.9.2. S-SBR
Fresh butadiene and styrene are received, stored, and blended with recovered
butadiene and styrene. The two chemicals, along with a catalyst and soap solution,
are pumped to the reactors where polymerization takes place. After the short-stop
stage, in which an agent is added to the mixture in order to stop the reaction,
20
 unreacted butadiene and styrene are recovered for recycling and pumped back to the
storage tanks. In the next stage, stripped latex is accumulated for blending, if
required. The latex is then coagulated and converted into crumb and screened,
washed, and filtered. Excess water is removed, and the crumb is dried in a hot-air
dryer. It is then weighed out in bales and wrapped in bags for shipment.
2.10. PTA
Paraxylene is oxidized to form crude terephthalic acid (CTA) in the oxidation section.
This CTA is purified by selective catalytic hydrogenation in purification section to form
purified terephthalic acid (PTA). PTA is a fiber intermediate, used for polyester
manufacturing along with MEG (Mono Ethylene Glycol).
2.11. Poly-phenylene sulphide
Poly-phenylene sulphide (PPS), a form of engineering plastic is composed of sulphur
and benzene. Benzene reacted with sulphur to produce phenylene-sulphide, which is
then polymerized to PPS. Poly-phenylene sulphide can be moulded, extruded, or
machined to high tolerances. This is 2 step process, pre-polymerization, followed by
polymerization.
2.12. Carbon Black
Carbon Black is produced by partial oxidation of highly aromatic oils like CSO from
FCC in a reactor. The reactor effluent is carbon laden flue gas along with some
combustible materials. Sensible heat from the flue gas is recovered in a waste heat
boiler to produce high pressure steam. Cooled flue gas containing carbon black
product is sent through bag filters to recover carbon black. Carbon black recovered
is sent to pelletizer and then to packing.
2.13. Calcined Petcoke and Graphite grades
Needle coke is produced using CSO from Petro FCC and MCC. It is further converted
to different grades of synthetic graphite.
2.14. Polysilicon / Chloro Silane
Polysilicon is produced from metallurgical grade silicon by a chemical purification
process, called the Siemens process. This process involves distillation of volatile
silicon compounds, and their decomposition into silicon at high temperatures.
Chlorosilanes are a group of reactive, chlorine-containing chemical compounds,
related to silane and used in many chemical processes
2.15. Petcoke gasification
The processing objectives for the expansion of Petcoke Gasification are:
• Support expanded crude oil refining and petrochemicals manufacturing, with cost
competitive, petcoke based energy supply
• Maximize reliability and availability of energy supply to the Jamnagar supersite
• Generate on-site syngas via petcoke gasification to minimize costly LNG imports
• Reform CO2, a gasification waste, to manufacture additional syngas, as
petrochemicals feedstock
• Minimize carbon footprint + environmental impact with clean syngas instead of
dirty petcoke/coal via petcoke gasification
• Supply syngas as an advantage feed for the C1 chemical complex.
The gasification is partial oxidation of coke with O2. Coke gasification reaction
converts coke into syngas. The primary constituents of syngas are CO and H2.
Syngas can be a gas turbine fuel, which can produce power in a combined cycle.
Syngas can produce hydrogen, C1 chemicals and oxygenated chemicals.
The major elements or processing sections for the IGCC project are:

21
 • Feed preparation to prepare petcoke slurry to feed gasifier
• Gasification, partial oxidation at very high temperature to generate syngas
• Effluent handling, to clean-up and cool raw syngas
• Sour block, to recover acid gases and generate sulphur
• Air Separation Unit (ASU) to supply O2
2.16. Metals recovery and Battery Manufacture
Batteries are basic components to ensure wide spread and efficient usage of
renewable energy. It is proposed to manufacture state of the art high capacity
batteries due to the resources available at Jamnagar. The high capacity batteries will
require raw materials like vanadium and Nickel.
Metals are natural ingredients of crude. In the refining and coking process these
metals are retained in the petcoke. In the process of Gasification of petcoke these
metals are retained in the petcoke cinder produced. The recovery of these metals like
Vanadium will provide valuable resources for the endeavor towards renewable
energy and India’s self sufficiency in valuable raw materials required for manufacture
of batteries using indigenously available materials.
Metals recovery is a combination of roasting + pyro-metallurgy + hydro-metallurgy.
Pyro-metallurgy can recover the metals as ferro-vanadium and Ni as ferro-nickel by
exploiting the eutectic temperature differences in a series of furnaces, to
progressively separate into metal phase. Further Hydro-metallurgy can recover V as
V2O5 from V rich intermediate sourced from the furnaces.
V2O5 is used as an electrolyte in large, stationery batteries to stabilize fluctuating,
renewable power grid. The metals so recovered are also important ingredients for
manufacture of stainless-steel.
2.17. Captive Co-generation Gas/Liquid Based Power Plant
A Gas / liquid based power plant based on the cogeneration concept of GTs, STGs
& boilers will be installed for captive power and steam generation, to support the
Jamnagar Oil-to-Chemical project.

22
 Chapter 3

Environmental
Aspects
3.0 Environmental Aspects
Environmental aspects and impacts is a way of ‘mapping’ the environmental
consequences of the project. Every project has environmental aspects that can have
it’s impact on air, noise, water, land, biological and social impacts. One of the most
important considerations of the project should be identifying various environmental
aspects. Once the aspects are identified, several techniques and methodologies are
in vogue for predicting anticipated impacts due to projects on natural and social
aspects of the environment. These predictions are superimposed over the baseline
(pre-project) status of the environment to derive the ultimate scenario of
environmental conditions. These conditions are then subsequently evaluated for
acceptability by screening them against standards for ambient environmental quality,
against toxic effect, thresholds, etc. Based on results of prediction and evaluation,
pollution abatement and control measures in order to mitigate the adverse impacts
on the environment are delineated in an Environmental Management Plan for further
implementation during the construction and commissioning of the proposed activities,
as well as during the operational phase.
Impact predictions are made against a 'baseline' established by the existing
environment (or by its future state) known as baseline studies, the collection of data
on relevant biophysical, social and economic aspects provides a reference point
against which the characteristics and parameters of impact-related changes are
analyzed and evaluated. In many cases, it is likely that the current baseline conditions
will still exist when a project is implemented.
The characteristics of environmental impacts to be taken into account in impact
prediction and decision-making include:
23
 i) Nature (positive, negative, direct, indirect, cumulative);
ii) Magnitude (severe, moderate, low);
iii) Extent/location (area/volume covered, distribution);
iv) Timing (during construction, operation, decommissioning, immediate, delayed,
rate of change);
v) Duration (short term, long term, intermittent, continuous);
vi) Reversibility/irreversibility;
vii) Likelihood (probability, uncertainty or confidence in the prediction); and
viii) Significance (local, regional, global)
3.1 Air Emissions
The impacts on air quality from any project depend on various factors like design capacity,
configuration, process technology, raw material/fuel used, envisaged emission control
measures, operational and maintenance practices. The emission rates of air pollutants
due to proposed operations will be considered for evaluating their impact. The licensors
will be required to meet the National standards prescribed for every unit proposed to be
set up. The stack details like stack height, stack top internal diameter, stack gas velocity,
stack gas temperature will also be defined to facilitate the impact prediction. In the
complex, stack emissions are the major source of air pollution. Additionally, the logistics
requirement will also be established so that the transport requirements and its impact can
also be evaluated.

3.2 Water Requirement and Wastewater Generation

3.2.1 Water Requirement
Considering the water shortage in the region, seawater will be used for the proposed
projects after desalination to meet the water requirement, which will be used for
various purposes viz. service water, fire water, process water, boiler feed water,
cooling water etc. The water required will be supplied by the proposed desalination
plants. For this purpose, seawater will be supplied to the desalination units. The
desalination units proposed at Jamnagar will be combination of Thermal Desalination
Plant and Reverse Osmosis Plant, based on availability of steam.
The water requirement for the complex is currently being met by desalination of the
seawater. The Ministry has granted CRZ approval for intake of seawater and
desalination facilities in 2015.

3.2.2 Waste Water Generation

The wastewater generated from the proposed projects will be characterized and
quantified through the licensors so as to design the required treatment methodology
to meet the National standards. The wastewaters generated from the processes, tank
drainage from the proposed project area and sanitary sewage will be treated at the
Effluent Treatment Plant (ETP) to be set up for the projects.
In order to maximise the re-use of the wastewater within the J Complex, the
wastewaters will be segregated into low total dissolved solids (LTDS), oily water
sewer (OWS) and high total dissolved solids (HTDS) streams etc. Interconnectivity
through the plants will need to be provided, to enable maintenance to be selectively
carried out on the equipment within each treatment train. The refinery wastewater
shall be collected via separate, dedicated effluent collection systems as required for
the optimum treatment and recycling.

24
 The ETP will be designed to cope with the maximum oil & solids loading and the
sludge removal should be robust enough to operate given these peaks. A diversion
system will be used to store high volume flows (over the design flow) to the ETP in a
guard tank within the ETP prior to treatment. The ETP will be properly designed
considering the influent characteristics of the wastewater from different streams. The
treated effluent will be reused in the cooling towers to reduce the water consumption
within the complex.
The return seawater from the proposed desalination plant and the reject stream from
the tertiary treatment facility of the ETP will be discharged through the return seawater
pipeline and diffuser, the location of which will be identified by NIO.The design of the
discharge system will be at a point so located as to give the maximum dispersion so
as to minimize the foot print of the discharge and thus the impact.
3.3 Solid / Hazardous Waste Generation
The solid / hazardous waste expected to be generated from the proposed project
operations will be delineated by the licensors so as to design the storage facilities for the
type of wastes generated. The disposal of the generated waste will be planned
considering the hierarchy of the disposal methods with reuse and co-processing given
the topmost priority.

3.4 Biological Environment

No protected areas or eco-sensitive areas are located within the proposed project area.
Given that the potential impacts of operation and commissioning of the project are likely
to be localised, and good site management practices will be implemented, no significant
effects are anticipated. However, greenbelt in the Jamnagar complex will be further
strengthened, which will be a positive impact in the region.

3.5 Socio Economic Environment

Considering the size of the project, the direct and indirect employment will increase
tremendously. Approx. 50,000 construction workers and 1,000 operational workers will
benefit from the proposed projects. The proposed projects will also provide indirect
employment to the local inhabitants. The construction workers will be housed in
properly designed worker accommodation which will have proper infrastructure
provided so as to minimize the impacts on the surrounding population.

25