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The document summarizes the Jamnagar Gasification Project at Reliance Industries' Jamnagar refinery in India. The project involves building the world's largest gasification complex to process 9.8 million metric tons per year of petroleum coke into syngas. The syngas will be used to fuel the refinery's power plant, produce hydrogen and synthetic natural gas, and provide feedstock to the adjacent petrochemical complex. When completed, the gasification project will help optimize the refinery's performance, increase margins, and further integrate the refinery and petrochemical operations.
The document summarizes the Jamnagar Gasification Project at Reliance Industries' Jamnagar refinery in India. The project involves building the world's largest gasification complex to process 9.8 million metric tons per year of petroleum coke into syngas. The syngas will be used to fuel the refinery's power plant, produce hydrogen and synthetic natural gas, and provide feedstock to the adjacent petrochemical complex. When completed, the gasification project will help optimize the refinery's performance, increase margins, and further integrate the refinery and petrochemical operations.
The document summarizes the Jamnagar Gasification Project at Reliance Industries' Jamnagar refinery in India. The project involves building the world's largest gasification complex to process 9.8 million metric tons per year of petroleum coke into syngas. The syngas will be used to fuel the refinery's power plant, produce hydrogen and synthetic natural gas, and provide feedstock to the adjacent petrochemical complex. When completed, the gasification project will help optimize the refinery's performance, increase margins, and further integrate the refinery and petrochemical operations.
13 - 16 th October, 2013 Colorado Springs, USA Gasification Technologies Conference 2013
2 Index Reliance Jamnagar refinery Integration Gasification Conclusion
3 Reliance: An introduction Performance; FY13 $bn Revenue/turnover 68.4 Exports 44.1 Earnings, EBDIT 7.1 Cash profit 5.6 Net profit 3.9 Net worth 32.7 Assets 58.0 Global Indian company Segment performance % Oil & gas Refining Petrochem Others Revenues 2.3 75.7 19.1 2.9 Earnings 15.3 53.5 29.9 1.3
Operates the worlds largest refinery @ Jamnagar Owns 25% of worlds complex refining capacity Among top 10 independent refiners Flexible in crude sourcing + product exports Generate higher margin per barrel, w.r.t peers Low cost producer of refinery products #1 in polyester, in the world #107 in Fortune Global 500 (2013)
4 Jamnagar refinery Worlds largest refinery + petrochemical complex Crude processing : 1360 kb/d (FY13), 1.8% of global refining Coker : 340 kb/d VR feed : 2 x 8 drum cokers, largest in the world : 6 mmt/yr petcoke production LNG import : 3.4 bcm/yr (FY13) Utilities & power : Cogen captive power plant, w/ GTG + HRSG : 1505 MW existing power + stm equiv. New projects : C 2 complex: 1650 kt/yr C 2 =, + 150 kt/yr C 3 = : Recover ethane + ethylene in RFG Crack ethane to ethylene + C 2 derivatives : Cracker + MEG + LDPE + LLDPE/HDPE : PX-4: 2330 kt/yr PX + 560 kt/yr benzene : Upgrade reformate to aromatics PX recovery + Isom + Transalky + Ex. Dist. 5 Gasification: Profile Configuration : Worlds largest w/ 10 gasifiers Feed : Petcoke, w/ coal blend flexibility Output : 8.0 bcm/yr syngas, NG equiv; 2.6 million Nm 3 /hr syngas Product : Cogen fuel : Produce power + steam H 2 : Eliminate on-purpose H 2 SNG : Refuel existing heaters Htr fuel : Fuel new heaters CO : Feed to acetic acid Driver : Substitute LNG w/ petcoke import
: Minimize refinery opex
: Boost refinery margin Worlds largest gasification complex 6 Refinery gasification integration Integrate refinery + gasification Refinery Gasification Existing New Petcoke Petcoke import Crude H 2 SNG Syngas/cogen fuel LNG import Syngas/htr fuel 7 Petchem gasification integration Integrate petchem + gasification @ Jamnagar Refinery Gasification PX-4 C 2 complex MEG LDPE LLDPE/HDPE Syngas/cogen fuel C 2 + C 2 = H 2 Crude Petcoke H 2 SNG Syngas/htr fuel Syngas/cogen fuel PX Benzene Reformate Existing New Syngas/cogen fuel Acetic acid Acetic acid CO Return 8 Demand profile Satisfy Jamnagar utility demand w/ syngas from gasification Cogen CPP Power + steam MW Integration Existing 1505 48% power + 52% steam equiv. New projects 350 All power Gasification 650 Parasitic, incl. stm equiv Total 2505 Cogen fuel demand Heater fuel RFG G cal/hr Existing 2010 SNG as fuel New projects 360 Syngas fuel for new htrs Total 2370 SNG + syngas demand H 2 H 2 t/d Capacity 1440 8 stm. methane reformer Existing demand 1175 On-purpose New project (400) H 2 from C 2 complex Total 775 H 2 from syngas 9 Driver
Petcoke : Lowest value refinery product : Bottomless refinery w/petcoke gasification Syngas : 100% captive consumption @ Jamnagar : Consumption = Cogen fuel, SNG/syngas as htr fuel, H 2 and CO : Beat LNG import price : Cost : Feed + opex + capex = Lifecycle $/mmbtu : 3.5 + 2.4 + 5.3 = 11.2 Refinery : Minimize refinery opex to boost refinery margin Petchem: Recover CO for new acetic acid plant : Swap SNG w/ C 2 + C 2 = in RFG, as advantage petchem feed Boost refinery margin + add value w/ petrochem 10 Project profile
Configuration : 10 gasifiers, in 5 modules w/ 2 gasifiers each : Large gasifiers @ 1170 MWth input/gasifier : Gasify petcoke to syngas Feed : 9.8 mmt/yr petcoke : 6.0 mmt/yr captive + 3.8 mmt/yr import : Feed flexibility, w/ 35% coal in blend : Upgrade petcoke Product : Syngas = 8.0 bcm/yr, NG equiv. : 100% captive consumption @ Jamnagar Max refinery + petrochem + gasification synergy 11 Product profile Syngas bcm/yr % Routing Cogen fuel 5.05 63 Existing + new GTG + HRSG H 2 1.3 16 Existing H 2 header/Hydrotreater feed SNG 1.1 14 Existing RFG header/Htr fuel Heater fuel 0.4 5 New htr. fuel CO 0.15 2 New acetic acid feed Total 8.0 100 Boost refinery + petrochem performance Gasification : Fuel + H 2 for refinery : Feed + fuel for petchem 12 Product summary Cogen fuel : Repower existing + new GTG + HRSG for captive power + steam : Power + steam = 2505 MW; existing =1505 MW, new = 1000MW H 2 : Supply H 2 for clean fuels, equiv. to 775 t/d H 2 : Shut down existing H 2 plants SNG : Recover C 2 +C 2 = to feed new Cracker in C 2 complex
: Substitute C 2 +C 2 = w/ SNG @ 2010 G cal/hr Heater fuel : Fuel all new process heaters w/ syngas @ 360 G cal/hr CO : Feed 450 kt/yr CO to new acetic acid plant By products : Sulphur Future proof : NH 3 recovery : CO 2 capture : Metals recovery Optimized gasification product slate 13 Energy flow diagram - schematic Gasification product slate Gasifier 100 25.8 Loss 8.8 Parasitic 4.9 53.6 2.7 5.0 25.0 6.5 54.6 Syngas/new htr fuel Syngas/ cogen fuel 1.0 1.7 10.6 SNG/existing htr fuel 12.4 12.4 H 2 Loss 6.1 125.8 Loss 0.9 Petcoke CO CO reco SNG Shift PSA 14 Configuration Optimized scope Gasification : 10 gasifiers, 5 modules w/ 2 gasifiers each ASU : 5 x 5250 t/d oxygen @ 99% OGBL : Package, # # Open art, # # AGR (unshift) 2 LTG cooling 2 AGR (shift) 2 Shift 2 PSA 1 SWS 8 CO recovery 1 SNG 1 SRU/TGT 4 SFU 2 OSBL : Offsites + utilities Offplot : Solids movement & storage 15 Partners Contractor: Licensor: PMC Fluor Gasification CB&I Lummus (Phillips 66) EPCM Fluor Open art Fluor O&U Bechtel Construction L&T Equipment suppliers: Reactor + vessels L&T Package suppliers: HTHR boilers Alstom ASU Linde Rod mills Cemtec AGR Linde Slurry pumps Geho/Flow serve PSA Linde Char filters Porvair SRU/TGT Worley Parsons Syngas rec. comp. Siemens SFU Enersul Superheater Linde/Selas GTG/GTG Mods GE Cooling tower SPIG Stacker/reclaimer Thyssen Krupp Partners-in-place for Jamnagar gasification project 16 Mega project # Gasification Associated Total PFD 5 x 9 70 115 P&ID 5 x 210 640 1690 Piping isometrics 5 x 5100 7800 43,300 Equipment 1060 480 1540 ODC equipment 110 15 125 Major EPC effort Source: Fluor Detailed engineering Task force : 400, to peak at 600 Man hour : 1.6 million Location : Fluor, Houston & Delhi 17 Capex Gasification % License, engineering, consultancy 5 Equipment + packages 48 Bulk material 16 Construction 14 Others (1) 7 Financing 5 Contingency 5 Total 100 Competitive capex Note 1: Others freight, startup + commission, duties + taxes, preoperative, insurance, inspection Jamnagar gasification = Projected at 75-83% of USGC capex 18 Status Project kickoff May12 PFD review Complete P&ID review + HAZOP Complete 30% model review Complete Equipment/package awards 90% complete (end Sep13) Detailed engineering 35% complete (end Sep13) Construction Commenced in Apr13 Target startup = mid 2015 19 Conclusions Make vs buy: Petcoke gasification (make) beats LNG import (buy) in India/Asia Bottomless refinery: Zero petcoke, lowest price refinery product Superior refinery margins Utilities: Repower cogen power plant w/ syngas Recover H 2 from syngas, for refinery clean fuels Utilize SNG + syngas as fuel for process heaters Petchem feed: Recover C 2 + C 2 = for petchem feed w/ SNG substitution Recover CO from syngas, for acetic acid Supply utilities to new petchem projects Success factor Min capex Meet or beat schedule Max availability Leverage gasification to boost Jamnagar refinery + petrochem performance Thank You Thank You