GAIL Auraiya

Unit Profile
GAIL (India) Ltd., Pata Petrochemical Complex is located at Distt. Auraiya in Uttar Pradesh. It is
based on Natural Gas as feedstock from GAILs HBJ pipeline, which has been set up in
accordance with GAILs mission to maximize the value addition from each fraction of Natural Gas.
The Plant consists of four major
units i.e. Gas Processing Unit
(GPU), Gas Cracker Unit (GCU),
HDPE and LLDPE Unit. Current
capacity of the cracker plant is
400,000 tonnes per annum of
Ethylene.
This acts as a
feedstock for the two downstream
units with an annual production
capacity of 100,000 TPA HDPE
and
2,10,000
TPA
of
LLDPE/HDPE
respectively.
GAILs product range comprises
of a wide range of Polyethylene
Products named as G-Lex and GLene (HDPE & LLDPE) grades,
which are used by plastic
processors to manufacture a large
variety of products for industrial, agricultural & domestic uses.
TECHNOLOGY
The Upstream (GPU & GCU) and Downstream (LLDPE &
HDPE) plants of GAIL, PATA are based on the best
technologies available in the world. Technology for the
Gas Cracker unit has been licensed by Stone and
Webstar, USA and Gas Processing Unit by M/s TFE.
Technology for the HDPE unit has been licensed by Mitsui
of Japan and Nova Chemicals, Canada for swing plant of
HDPE & LLDPE unit. Ethane, a constituent of Natural Gas
is converted into ethylene as its main product in the Gas
Cracker Unit based upon latest technology from USA.
Ethylene is feedstock for 02 downstream units namely,
HDPE plant and Swing LLDPE/HDPE Plant. Butene-1
used as co-monomer in production of HDPE & LLDPE is
produced in Butene-1 plant licensed by M/s Axens, USA.

LPG RECOVERY PLANT

LPG Recovery Plant is an integral part of GAIL,
Pata. This is an example of Project management
as this unit was put on production five and half
months ahead of schedule without any additional
manpower.
The Gas received from HBJ Pipeline is first
sweetened in Gas Sweetening Section of GPU,
which is then expanded and cooled in C2/C3

Recovery Section of Gas Processing

Unit so as to get liquid hydrocarbon
containing Ethane, Propane, Butane,
Pentane,
Hexane
&
heavier
components of Natural Gas.

Lean
G

Natural Gas

C1

Ethane

C2

Butane

C3

Propane

C4

Pentane

C5

Pentane

C6

SBP

C2/C3

Liquid hydrocarbon extracted in GPU

is further processed and fractionated
in LPG Recovery Plant, which is
integrated with GAIL, Pata to produce
C2/C3 for Gas Cracker feed, LPG,
Propane, SBP Solvent and Pentane.

LPG

Process Flow Chart

12 MMSCMD
RICH GAS
FROM HVJ/
VIJAIPUR

GAS
SWEETENING
UNIT (TFE)

11.35
MMSCMD

9.3 MMSCMD

440,000 TPA
ETHYLENE

C2/ C3
RECOVERY
UNIT (EIL)

LEAN GAS
TO AURAIYA
COMP.STN.

LLDPE/HDPE
SWING UNIT
(NOVA)
210,000 TPA
HDPE UNIT
(MITSUI)
100,000 TPA

GAS CRACKER
UNIT (SWEC)
C2/C3

LPG
UNIT (EIL)

BUTENE 1
UNIT (AXENS)
10,000 TPA

258,250 TPA of LPG

71,000 TPA of Propane

Energy Consumption

Year

Prod.
MT

Energy Consumption

Specific Energy Consumption

2003-2004

553,305

Lakhs
kWh
2607

2004-2005

594,266

2702

4103518

455

6.91

2005-2006

577,358

2735

3983561

474

6.90

Year

Product

2003-2004

Polymer+
LPG+
Propane

2004-2005
2005-2006

MKCals

kWh/ Tonne

MkCal/ Tonne

3730609

471

6.74

kWh/
Tonne

% reduction
over
2002-2003

MkCal/
Tonne

% Reduction
over
2002-2003

471

5.23

6.74

2.17

455

8.5

6.91

-0.29

474

-4.24

6.90

0.14

Specific Energy Consumption trends of Ethylene and Final Products

HDPE Specific energy cons.

Ethylene Specific energy cons.

5000

800

KWH/MT

KWH/MT

1200

2000

400
02-03

03-04

Global Best

04-05

Global Average

05-06
Actual

02-03

03-04

Global Best

04-05
Design

05-06
Actual

Energy consumption of polymer products HDPE, LLDPE as well as intermediates ethylene is

being monitored closely with respect to design figures and benchmarking figures. Over the past
four years, HDPE and LLDPE specific energy consumptions have come down from 1120
KWh/MT to 967 KWh/MT and from 1650 KWh/MT to 1117 KWh/MT respectively.
LLDPE Specific energy cons.
KWH/MT

2000

1000

0
02-03

03-04

Global Best

04-05
Target

05-06
Actual

Energy Conservation Commitment, Policy and Set up

GAIL, Pata is a major player in petrochemical sector. Natural gas being used as feedstock also
serves the purpose of fuel. With the increasing price of fuel gas, energy conservation is of prime
importance for us. Specific energy consumption targets are set every year, which are monitored
at the top management level in the organization. Benchmarking parameters with respect to
specific energy consumption of intermediate product like ethylene and final products HDPE &
LLDPE are set, which are monitored by corporate office on monthly basis.
Process optimizations as well as plant modifications are encouraged by the management in order
to reduce energy consumption. We have suggestions scheme for innovative schemes in place in
our organization.
Energy policy is available and a full fledged energy management services group functions for
process improvements and energy conservation.
GAIL Pata is carrying out energy audits every year. M/s PCRA and M/s Forbes Marshall were
hired to carry out energy audits at GAIL Pata. As a part of in-house capacity building, GAIL, Pata
is nominating its executives to undertake Energy Auditor exam conducted by Bureau of Energy
Efficiency every year. As on date, we have ten nos. of certified energy auditors and sixteen more
candidates have undergone examination this year. Encon studies are conducted by plant
employees.

Oil and Gas conservation fortnight is celebrated every year in January with an objective to create
mass awareness among employees, their families, school children and adjacent community.

Energy Management Policy

GAIL, Pata is committed to efficient and optimal use of energy resources in all its
applications and services through effective energy management with focus on
productivity, cost effectiveness, environment and a better tomorrow.

Energy Cell Structure

Executive Director (Petrochemical

Complex) & Officer-in-Charge

DGM (Electrical) & HOD

(Energy Management Services Group)

Chief Manager
(Energy Management Services Group)

Senior Manager
(Energy Management Cell)

Engineers (Proposed in
future)

Energy Conservation Achievements

1. Refractory repair was carried out for four nos. furnaces in Gas Cracker Unit in Nov 05
shutdown A reduction in specific consumption of fuel in GCU furnaces due to refractory
repair and increased ethylene production achieved equivalent to energy saving of 32677
MMKcal and cost savings of Rs. 1.67 crores in 2005-06.
2. Process optimization (Dilution steam to hydrocarbon ratio) carried out since Jan 06 has
resulted into reduction in fuel gas consumption in GCU furnaces equivalent to energy saving
1415 MMKcal and cost saving of Rs. 49 lacs in 2005-06.
3. Door limit switches in electrical substation lighting circuits have been installed in Jan 06,
which have started yielding energy savings of Rs. 1000 per day (Rs. 3.65 lacs per annum).
Total energy savings achieved in 2005-06 is 16,100 KWh equivalents to Rs. 0.7 lacs.
4. Reduction in operating hours of cooling water pumps based on environmental conditions in
LPG has resulted into savings of 12 MWh per day, which translates into savings of Rs. 61
lacs per annum (Considering operating hours reduction for 6 months duration in a year).

5. Optimization of amine flow in Gas Sweetening Unit was carried out in Dec 05, which has
resulted into benefit of steam savings equivalent to 2000 MT of steam per month equivalent
to savings of Rs. 33 lakhs in 2005-06.
6. M/s Forbes Marshall carried out Energy Audit for steam traps and condensate recovery
system. Based on the recommendation of the audit, around 300 steam traps were replaced
and the recommendations for condensate recovery are under implementation. Overall
reduction in steam consumption by 22,100 MT compared to 2004-05 has been achieved
resulting into annual savings of Rs. 88.4 lacs.

Energy Conservation Plans and Targets

Anticipated savings
Energy Conservation Measures
(Planned)
Energy Value
(specify units)
Flare Gas recovery system using
ejector
Ethylene Boil off Gas diversion to
HDPE units
Ethylene sphere vapor diversion to
HDPE units
Hydraulic Pressure Turbocharger
in Gas Processing Unit
Advanced Process Control
Implementation

Rs. Lakhs

Approx.
investment
(Rs.lakhs)

Project
Commencement &
Completion year

132894
MMKcal/Year

650

1072

2007-08

19,328,000 KWh

1600

985

2007-08

9,091,699 KWh

410

30

2006-07

5,040,000 KWh

282

676

2007-08

Installation of additional STG

72,000,000 KWh

700

1800

2007-08

Cooling tower pumps internal

coating

2,803,200 KWh

79.6

51

2006-08

23

15

2006-07

Reduction in ethylene compressor

power consumption

858,000 KWh

Details of the projects:

1. Flare Gas Recovery Project: This project is aimed at recovering flare gases going into flare
system for ultimate use as fuel gas in boilers. The project consisting of gas compression
system and associated piping etc. is being implemented through an EPCM consultant M/s
Lurgi India. The estimated expenditure of the project is Rs. 10.72 Crores. The implementation
of the project would result into fuel savings to the tune of Rs. 6.5 Crores per annum. (Energy
saving of 132894 MMKcal/year).
2. Ethylene boil off gases diversion to HDPE units: This project will reduce recycling cost of
ethylene by diverting it to HDPE units. The project comprises of a compressor and associated
piping etc. The project costing Rs. 9.85 Crores will result into energy savings of Rs. 5.3
Crores annually. Additionally, ethylene production will increase, resulting into more polymer
production equivalent to production benefit of Rs. 10.8 Crores. (Energy savings per year will
be 19328 MWh)
3. Diversion of sphere vapor to HDPE units: Ethylene vapor from sphere which is presently
being recycled back to GCU will be diverted towards HDPE units to save recycling energy
cost to the tune of Rs.4.1 Crores per annum. Additionally, ethylene production will increase,

resulting into more polymer production equivalent to production benefit of Rs. 8.0 Crores.
(Energy savings per year will be 9091 MWh)
4. Hydraulic pressure turbocharger in Gas Processing Unit (GPU): This project is
envisaged to recover pressure energy from amine stream in GPU employing the latest
technology. With an estimated investment of Rs. 6.76 crores, the project would yield energy
savings of Rs. 2.82 crores per annum. (Energy saving per year will be 5040 MWh).
5. Advanced Process Control (APC): This project is under implementation for upstream units
(GPU/GCU/LPG) with an investment of Rs. 7.5 Crores After implementation of the project, it
is expected to reduce the specific energy consumption to the tune of 3% in these units.
6. Installation of additional STG: Installation of a 9 MW extraction type STG unit with an
investment of Rs. 18 Crores has been approved. The installation of extraction type STG
would enable efficient use of VHP steam to produce HP steam and also in power generation
which will reduce dependence on state grid and make savings of Rs. 7 Crores per annum.
7. Cooling tower pumps internal coating: In order to reduce frictional and hydraulic losses
inside cooling tower pumps, cooling tower pumps internal coating will be carried out for 16
nos. pumps. For each pump, at an investment of Rs. 3.2 lacs, power savings will be 20 KWh
(Rs. 5 lacs every year).
8. Reduction in ethylene compressor power consumption: A project is under study to save
energy in Ethylene compressor of LLDPE plant. With an investment of Rs. 15 lacs, the
annual energy saving is estimated at Rs. 23 lacs per annum. Energy saving per year will be
858 MWh.
9. Vent CO2 utilization: Utilization of CO2 vent gas from Gas Sweetening Unit is being
conceptualized and feasibility studies are being looked into by Corporate Office.
Other energy savings initiatives taken up are:
1. Reduction in steam losses
2. Installation of variable frequency drives to reduce power consumption
3. Replacement of under loaded motors with suitable rating motors
4. Reduction in compressed air consumption.
5. Reduction in nitrogen consumption.
Environment and Safety
GAIL is committed to the cause of, Safety Health & Environment. At GAIL, PATA a well defined
Safety, Health & Environment Policy has been formulated, distributed and displayed. Safety of
personnel and plant, preservation of the ecology and environment in and around its plant is a
priority area of GAIL and UP Petrochemical too.
GAIL, Pata has been accredited with the Quality Management Systems (ISO 9001),
Environmental Management Systems (ISO 14001) & Occupational Health & Safety Management
Systems (OHSAS 18001).
Environment
GAIL, Pata is committed towards Sustainable Development. In line with its commitment GAIL has
given topmost priority to environment
protection throughout the project including the
phases of Technology selection, process
design and project execution.
Elaborate Waste Water Treatment Plant
(WWTP) facilities have been set up to treat
effluents from all the processing plants and

utilities at the Complex and to meet MINAS (Minimal National Standards).

The status of pollution, if any, including the water, solid and air in and around the Complex is
constantly monitored by the third party consultant. The quality control laboratories are fully
equipped with all the necessary equipment to ensure that effluents being released by the plants
meet the MINAS specifications. Apart from this, more than 5 lacks trees have been planted in the
area of about 180 hectares in and around the plant. This is despite the extremely inhospitable
soil and terrain in the area.
GAIL, Pata has bagged Greentech Gold Environmental Excellence award for 2001-02, 2003-04,
2004-05 and 2006. Recently, GAIL, Pata received Golden Peacock Environmental Management
award for year 2006.
Safety
Safety is ensured through proper designed, layout, construction and best operation and
maintenance practices. National & international standards are followed in all above areas.
Entire complex is covered through a network of Fire Water Header approximately 46 kilometers n
length, containing water at 8.5 Kgf/cm2 at remotest point from pump house, exclusively for fire
fighting. We have large fire water reservoirs (106000 cubic meter capacity) and dedicated Fire
Water Pump House with 9 main and 3 jocky pumps, to take care of two major fires in the complex
at a time. We have full fledged modern Fire Station manned round the clock with qualified &
experienced Fire & Safety Personnel.
External and Internal safety audits are conducted on regular intervals. Risk Assessment analysis
for GAIL, Pata was carried out by M/s Tebodin, Netherland last year. OISD audits have been
conducted recently last month for GAIL, Pata.
GAIL, PATA is proud winner of Sword of Honour from British Safety Council, U.K. which is one of
the highest recognitions for our commitment to the safety. In addition to this, GAIL, PATA has
been bagging National Safety Award from BSC, UK for last six consecutive years. We have also
been honoured with Green Tech. Gold Award for industrial safety.

1. Refractory repair in four nos. furnaces in Gas Cracker Unit.

above 180 degC required to be attended immediately and the same were attended during
shutdown.

Routine checking of insulation of Gas Cracker Furnaces is carried out by inspection department
on quarterly basis. Hot spots were observed at several places in the furnace insulation. The hot
spots

It was decided to repair the refractory in the forthcoming shutdown and the same was carried out
for four nos. furnaces in Gas Cracker Unit in Nov 05 shutdown. A reduction in specific
consumption of fuel in GCU furnaces due to refractory repair and increased ethylene production
achieved equivalent to energy saving of 32677 MMKcal and cost savings of Rs. 1.67 crores
during four months period in 2005-06.
2. Optimization of Dilution Steam to Hydrocarbon ratio in GCU furnaces
Dilution steam was optimized in Gas Cracker furnaces. Process optimization (Dilution steam to
hydrocarbon ratio) carried out since Jan 06 has resulted into reduction in fuel gas consumption in
GCU furnaces equivalent to energy saving 1415 MMKcal and cost saving of Rs. 49 lacs in 200506.
3. Door limit switches in electrical substation lighting circuit
Lighting in the unmanned substation remained on during night hours. Therefore, door limit
switches in these electrical substation lighting circuits have been installed in Jan 06, which have
started yielding energy savings of Rs. 1000 per day (Rs. 3.65 lacs per annum). Total energy
savings achieved in 2005-06 is 16,100 KWh equivalent to Rs. 0.7 lacs.
4. Reduction in operating hours of cooling tower water pumps in LPG unit
During winter season, it was observed that process heat load is low and cooling water
requirement becomes less. Therefore, it was decided to stop one cooling water circulation pump
of cooling tower in LPG unit.
Reduction in operating hours of cooling water pumps based on environmental conditions in LPG
has resulted into savings of 12 MWh per day, which translates into savings of Rs. 61 lacs per
annum (Considering operating hours reduction for 6 months duration in a year).

5. Reduction in steam consumption

Overall reduction in steam consumption by 22,100 MT compared to 2004-05 has been
achieved resulting into annual savings of Rs. 88.4 lacs.
(A) Rectification of steam traps
As per the recommendation of M/s Forbes Marshall Audit, around 300 nos. of defective steam
traps were rectified in 2005 shutdown.

(B) Reduction in steam consumption in Regenerator Reboiler

The regenerator reboiler uses LP steam available at a pressure of 4.5 kg/cm2a and a temperature
of 165oC for stripping of CO2 from amine solution. The LP steam is desuperheated to produce
saturated steam before entering the reboiler in a desuperheater using condensate spray.
However, because of excess passing of condensate, control of the steam temperature during
operation was not accurate with the result that the steam was getting sub cooled. A new
temperature control valve was installed and the steam temperature maintained near its saturation
temperature, by regulating the flow of condensate through the temperature control valve.
This modification has led to maintaining of the steam temperature at 145 DegC and reduction in
steam consumption by 10 MT/Hr. The modification was implemented in Dec 05 and savings of
Rs. 33 lacs was achieved in 2005-06.