Reliance Industries Ltd, Refinery Div, Jamnagar

Unit Profile:

Reliance, Jamnagar is the largest grass root refinery set up with annual capacity of 27 million
tons and the 3rd largest refinery in the world at any single location.

The refinery and Petrochemical Complex comprises of Crude Unit (2 parallel trains), Diesel
Hydrotreator (2 trains), VGO Hydrotreator (2 trains), Sulfur (3 trains), Hydrogen (2 trains),
Coker, Fluid Catalytic Cracker, Propylene Recovery Unit ( 2 trains), Amine treating Unit,
Desalination Units, Naphtha Hydrotreating, Catalytic Reforming, Paraxylene Extractions trains
(3 nos), Tatoray Unit, Xylene extraction, Iso Benzene unit, ED unit, Polypropylene Unit (4
trains), Captive Power Plant, RO plant and a Effluent treatment plant. Block flow diagram of
the complex is attached.

Highlights:

9 Largest Grass Root Refinery.

9 World’s Largest FCCU – 10.05 MMTPA (200 KBPSD).
9 World’s Largest Coker – 8.3 MMTPA (163 KBPSD).
9 World’s Largest Aromatics Complex – 2.1 MMTPA (PX + OX) capacity in one site.
9 World’s largest PP in one site – 750,000 MTPA
9 India’s largest Sulfur Recovery Complex – 1350 TPD
9 Large size Captive Power Plant 450 MW Capacity (Power) and 1875 MT/Hr (HHP
Steam)
9 India’s largest Petroleum Terminal, Oil movement and Storage area.
Energy Consumption

Year Sp Power Cons Kwhr/MT of Thermal Consumption Mkcal/MT of Intake

intake
2003-04 73.49 0.661
2004-05 73.1 0.662
2005-06 74.23 0.668

In the Refinery Energy monitoring, the practice of evaluation of Energy Index is prevailing. An
Energy Index is the ratio of actual energy consumed and the standard or theoretical energy
consumed. Lower the Energy Index better is the Energy Efficiency.

In Energy Indices evaluation, the feed stocks of all the processing units are considered and
the energy Index arrived at by International Systems such as either Shell or Solomon
Benchmarking normalizes all the specific energy consumption and the reduction in the Index
Indicates true reduction in the energy consumption. Following are the Energy Indices for
Reliance Jamnagar

Shell Benchmarking Solomon Benchmarking

Year CEL* Year EII*
2001 94.3 2000 69.2
2002 88.7 2002 64.2
2003 87.6 2004 62.3
2004 86.9
2005 89.5

Reliance Jamnagar is topping the list of Shell Benchmarked Refineries in the world and also
topping the list of Large Complex Refineries in Solomon Benchmarking in the Asia Pacific
Region for last five years. Reliance Jamnagar is the pace setter refinery in the field of energy
conservation in shell and Solomon benchmarking continuously since last five years. Increase
in CEL in year 2005 is due to the major VMP shutdowns taken for regular maintenance,
Capacity enhancement and commissioning of new units.

Energy Conservation Commitment, Policy and Organizational Set up

Reliance has a comprehensive policy on energy conservation. Innovative energy

conservation practices are practiced all throughout the site. Better operating practices,
improved operating efficiencies, optimum utilization of resources increased automation,
introduction of advanced control systems, new techniques and technologies, higher capacity
utilization are the various methods used which aim at the corporate goal or commitment to
conserve / optimize energy consumption .The Company’s Energy Management policy is
attached.

Energy Management Set-up

At Reliance Jamnagar on a continuous basis, a detailed review is made at sector chief levels
fortnightly with complete focus on Energy Consumption. A rigorous plan is generated by
Central Technical Services for implementation of the various projects which are being
implemented or are planned in future. Top, middle, junior management and workmen of all
level are committed and involved to meet the same corporate goal. The Energy conservation
team structure which works out together for implementation of the projects is shown in figure
below:
Energy Conservation Organogram:

SITE PRESIDENT

SENIOR VICE PRESIDENT

CENTRAL TECHNICAL
SERVICES

ENCON. TEAM LEADER

ENCON. ENGINEERS

PLANT MANAGERS UNIT TECHNOLOGISTS

PLANT ENGINEERS

PLANT OPERATORS
 Major Encon Projects in 2005-06

Project detail Sr. No. 1

Reduction of MP steam consumption by using LCGO Pump Around as Heating Medium

in Parallel Naphtha Splitter Reboiler in Coker

Coker Fractionator top temp. was raised from the original design of 113°c to 122°c to reduce
the surface area getting effected due to corrosion in the top section of the Fractionator from
Ammonium Chloride deposition on to the wall & trays due to high nitrogen in feed (Vacuum
Residue). This along with separate Kerosene Draw off nozzles enable to increase the Draw
off temp of LCGO Pump Around & LCGO Product to 244°c from original design of 194°c .If
the Original design equipment set up was not modified this energy would have got wasted to
atmosphere with the help of Fin fans 371A07 & 371 A08C as shown in fig 1.

This opportunity was utilized to divert this hot LCGO Pump Around stream first through
Parallel Naphtha Splitter Reboiler 372S07A and off loading the heat duty of the Existing
Naphtha Splitter Reboiler using Medium Pressure Steam as the heating medium (see fig2)
after which the existing route was retained ,
The series of exchangers that comprise this circuit are as listed below

ME-RK372-S07A Naphtha Splitter Reboiler ( LCGO Pumparound as Heating edium )

ME-RK371-S05 LCGO Pumparound /LP Steam Generator

ME-RK371-S04 LCGO Pumparound /BFW Exchanger
ME-RK371-A07 LCGO Pumparound Cooler
ME-RK371-A08C Condenser Cooler

Since recoverable heat from the LCGO Pumparound circuit had greatly increased from the
original design . There was no modifications carried out on existing equipments in the LCGO
Pump Around loop. This resulted in off loading the existing Naphtha Splitter Reboiler to the
tune of 9TPH which equivalent to (heat duty ) thermal saving of 6.1MMKCal/h at present
throughput. This scheme also increased the LCGO Product temp. to the downstream Diesel
Hydro treating units as shown in the graph below, which is equivalent to 0.485MMKcal/Hr. In
order to have greater flexibility at higher plant throughput & in view of presence of corrosive
substance like Ammonium Chloride in LCGO Pump Around the option of using it as heating
medium in the Parallel Naphtha Splitter Reboiler ME-RK372-S07A was frozen.(Fig3)
EXISTING SCHEME:

MODIFIED SCHEME:
Heat Duty Q = 6.1MMKCal/hr
Steam Saved = 9TPH
Annual Savings due to MP Steam savings in Naphtha Splitter Reboiler = 35.7 RS Million.
Fuel Savings in downstream Hydrotreaters due to high temperature LCGO = 6.425 RS Million
Total Annual Savings = 42.125 RS Million

The following graph indicates the reduction trend of MP Steam consumption (TPH) to the Old
Naphtha Splitter Reboiler.

Using LCGO Pump Around as

Heating Medium in Parallel Naphtha
Splitter Reboiler 372S07A
CONSUMPTION IN TPH

3 20
7
2
MP STEAM

15 Savings 9TPH
F MP Steam
I
C 10
0
3 5 Before After
9
0
6
6

06

6
00

00

00
20
/2

/2

/2
6/
20

27

13
3/
2/

2/

3/

DATE

The following graph indicates the increase in temp. of LCGO Product to downstream unit .

Increase in LCGO Product Temp.

LCG0 Product

3
260
Temp.°C

7
240 1
220 T Series1
200 I
180 0
10.11.20

24.11.20

08.12.20

22.12.20

05.01.20

19.01.20

02.02.20

16.02.20

02.03.20

16.03.20

4
6

Date
Some of the challenges that were overcome in the course of design & execution of the Project
are as follows
In view of the tight shutdown schedule it was proposed that no new nozzles will be added on
to the Naphtha Splitter & only the existing nozzles to be augmented in the design stage only
which made it mandatory to modify vapor outlet lines of existing Naphtha Splitter Reboiler.
During the course of Detailed Engineering it was found that the Reboiler vapor lines two
phase was in Wavy Stratified flow regime & the rerouting needs to be modified to get in two
phase regime to Annular flow.

Moreover, to commission this system, an innovative method of Hot-tapping had to be adopted

for cutting the blind flange at the installed at Naphtha Splitter Vapor nozzle along with the
valve during the earlier shutdown (Oct’05) as valve was heavily passing and conventional way
of deblinding will require shutdown of unit.

Conclusion:
Using LCGO Pump Around as heating medium to Parallel Naphtha Splitter Reboiler 372S07A
was successfully commissioned in Coker and the summary of findings of the system is as
follows
1) Reduction of MP Steam Consumption in existing Reboiler by 9 TPH which is
equivalent to 3.57 c crores per annum.
2) Reduced the increase Power consumption in the Fin Fan 371-A07 & 371A08C at the
increased throughput.
3) Increase in LCGO Product temp. to downstream hydro treating unit to 237°c, which is
equivalent to 0.485MMKCal/hr (0.6425 Crores Per annum) .
Project detail Sr. No. 2

MP steam consumption reduction in CDU by commissioning of S-41 Exchanger in 312

utilizing heat from hot HK product to preheat crude

Objective:

To recover Heat from HK product from 312/311 which was being lost in Fin fan coolers before
being routed to Diesel Product Storage Tank? It was decided to locate this new w exchanger
S – 41 in the upstream of S-03 in Cold preheat train. The exchanger is designed to recover 9
MMKcals/hr of heat from HK product to Crude. This scheme will be applicable only during
0.25 % S in Diesel run. During Diesel BS-II & BS III runs as HK from CDU-1 & 2 is routed to
DHT, this Exchanger S-41 will be bypassed and hot HK will be routed to DHT.

Methodology:

There was a emergency s/d on the 2nd of March 06 in CDU-2 due to power tripping caused in
CPP. The emergency s/d & subsequent startup led to a leak in S-03 Exchanger which
resulted in a decrease in Desalter Temperature & subsequent loss of Crude Preheat which
also resulted in decrease in Crude throughput by 50 m3/hr. This necessitated early
commissioning of S-41. The exchanger was commissioned in March – 06.

Details of key operating parameters before implementation (Feb 2006) and after
implementation (March 2006) are given in the Table below:

Sr Parameter Before Installing After S-41 Units

No S-41 Exchanger Exchanger
c
1 Crude Throughput 305 307 Kbpsd
2 Crude Preheat temperature 244 246 Deg C
3 Desalter temperature 116 127 Deg C
Benefits Achieved

Actual Benefits

Recovery of 9MMKcals/hr of heat which 0.9 T/hr of Equivalent Fuel in TSRF ( 1 kg =10 000 Kcals)
was being lost to atmosphere i.e Fin Fan
Cooler

Cost of Fuel 250 $/Ton

Benefits on account of Fuel =0.9 x 250 x 24 X 365 X 45/10000000
=8.87 Crores /annum

Increase in Throughput is 2Kbpsd =2 x 5 x 45 x 24 x 365/10000000

=0.39 Crores/annum

Total Benefits 9.26 Crores/annum

Cost of Project was Rs 1.98 Crores

Benefits 9.26 Crores

Pay back = 2.5 months

Conclusion:

Commissioning of new preheat exchanger S-41 for heat transfer from HK to crude resulted in
the saving of 0.9 T/hr of fuel or 7884 T/yr fuel.

It also resulted in the increase in Crude throughput by 2 KBPSD.

Project detail Sr. No. 3

Online chemical cleaning of Crude Furnaces

(A) Introduction:

In the second week of June’05, Throughput and Coil outlet temperatures had to be reduced to
1950m3/hr and 365degC respectively in Unit-311. Unit –312 throughput and COT had to be
reduced to 2030m3/hr and 365degC because of high BWT 865degC.Heater duty also came
down as given in table below due to low radiant heat flux.

Heater duty (MMKcal/hr)

Heater From To
311F01 110 100
311F51 115 95
312F01 110 98
312F51 115 95

Fouling on heater tubes caused low radiant heat flux and increase in BWT to 865degC.Heat
duty could not be raised because of limiting BWT.
Furnace tubes in crude furnaces, viz. 311/312 F01 (Zone 1 and 2) & 311/312 F51 (Zone 1
and 2) have deposits of catalyst dust coming from fuel oil fired in the furnaces. The coating is
in the form of fine powder, white in colour. This coating has further aggravated the problem of
high bridge wall temperatures in the furnaces. As a result, Unit-311/312 throughput had to be
restricted to hold the BWT below 865degC. As an online solution, CTP France was
commissioned to carry out online chemical cleaning of radiant and convection section tubes
of crude furnaces.

(B) Methodology:

♦ CTP carried out chemical injection in the radiant and convection section, in that order, of
311 F01 Zone 1 & 2 and 311 F 51 Zone 1 & 2. The cleaning was carried out during 4th
July’2005 to 26th July’2005.
♦ Chemical injection was carried out by keeping the stack damper open and ID fan stopped.
Chemical injection was carried out in two shits between 0500 hrs and 2100 hrs.
♦ Injection of the chemical was done with the help of compressed air/ MP steam.
♦ Chemical injection in zone was completed only on advice of vendor
♦ ID Fan guillotine was not inserted while cleaning

(C) Observations:

Cleaning Performance indicators of 311/312 F01, F 51 and F02, covering the period prior to,
and after cleaning are tabulated below:
UNIT-311

No Description From To Remarks

1 311 F 01 4th July’2005 9th July’2005 Cleaning stopped on 5th July 19:00hrs due to
machine breakdown and resumed on 8th
morning. Convection tubes cleaning were
carried out in F01/F51 during m/c break
down period.
2 311F51 11TH July’2005 13th July’2005

3 311 F02 13th July’2005 15th July’2005 Minor damage observed on tube heat shield

UNIT-312

No Description From To Remarks

 1 312 F 01 16th July’2005 19th July’2005

2 312F51 20th July’2005 23rd July’2005

3 312 F02 24th July’2005 26th July’2005 CTP was instructed to take special
precaution to avoid any damage to heat
shield

Temperature profile:

UNIT-311

Temperature profile before after cleaning

BWT (degC) Temp. Drop Normalized

(degC) temp.drop
Before After After After

1 311 F 01 Zone 1 895 827 68 78.5

2 311 F 01 Zone 2 895 802 93 140

3 311 F 51 Zone 1 888 791 97 79

4 311 F 51 Zone 2 891 801 90 90.5

5 311 F02 877 777 100 77

UNIT-312

Temperature profile before after cleaning

BWT(degC) Temp. Drop Normalized

(degC) temp.drop*
Before After After After

1 312 F 01 Zone 1 874 779 95 103

2 312 F 01 Zone 2 888 783 105 95

3 312 F 51 Zone 1 882 813 69 80

4 312 F 51 Zone 2 895 814 81 105

5 312 F02 880 832 48 42

Basis adopted for normalization of BWT drop after cleaning, as we have not brought the
operating conditions same as before cleaning.
• 1 m3/hr increase/decrease in Throughput~ 0.5 deg increase/decrease in BWT.
• 1 degC increase/decrease in COT ~ 2.0 deg increase/decrease in BWT.
(D) Analysis:

Comparison of operating conditions before and after cleaning is tabulated below to analyze
benefits incurred after cleaning.
 Throughput Preheat F01/F51 COT F02 COT F01/F51 BWT F02 BWT
UNIT-311
m3/hr degC degC degC degC degC
Before Cleaning 1954 233 364 372 865 865
After Cleaning 2032 231 377 380 812 790

Throughput Preheat F01/F51 COT F02 COT F01/F51 BWT F02 BWT
UNIT-312
m3/hr degC degC degC degC degC
Before Cleaning 2030 238 365 371 865 865
After Cleaning 2110 239 377 382 804 845

Unit-311: Benefits of CTP cleaning are clearly seen in above table in increase in throughput,
coil outlet temperatures and reduction in Bridge wall temperature. Throughput and COT
increased by 78m3/hr (11.8kbpsd) and 13degC respectively. Vacuum furnace outlet
temperature increased by 8degC. BWT reduced from 865degC to 812 degC in crude furnaces
and from 865 degC to 790 in VDU furnace.

Unit-312: Benefits of CTP cleaning are clearly seen in above table in increase in throughput,
coil outlet temperatures and reduction in Bridge wall temperature. Throughput and COT
increased by 80m3/hr (12kbpsd) and 12degC respectively. Vacuum furnace outlet
temperature increased by 11degC. BWT reduced from 865degC to 804 degC in crude
furnaces and from 845 degC to 790 in VDU furnace.
Additionally, operating Furnace at lower than design BWT high limit will ensure better
reliability.

(E) Conclusion:

♦ Based on the data presented in the tables above and operating data before and after
cleaning, it can be concluded that the chemical injection has given benefit in terms of
reduction in BWT, indicating a better heat pick up in the radiant section of the furnace.
Hence the constraint of max BWT on thruput has been removed. On account of this
cleaning, 307 kbpsd and 319kbpsd throughput could be sustained in 311 and 312unit
respectively with average reduction of VGO dropping in VR from 6.0% to 3.5%.
♦ Approximately 78 m3/hr per unit of additional crude thruput can be processed with a
margin of ~ 50-60 o C in the BWT. Assuming the benefits to last for at least three months,
the benefits on account of cleaning would be ~ Rs.48.0 Crores. Payback benefit on
account of improved COT and subsequently improved VGO recovery has not been
considered.

Project detail Sr. No. 4

Cooling Tower - Energy- efficient FRP Fan Replacement

Introduction:
Under the energy saving scheme FCO/Utility/206, replacement of cooling tower Paharpur
fans by axial flow energy efficient fans was planned. Replacement of 30 numbers of fans for
cooling tower – 1, 2 and 4 was included in the above PCO. 10 numbers of Paharpur made
fans were replaced by Parag made FRP blade fans after taking trial of 8 blade fans. But
following complaints have been reported on Parag made FRP fans by Utility maintenance:
1. Shearing of fan central bush bolts
2. Peeling of the resin from Parag fan blades
Vendor M/S Parag did not resolve the above issues after repeated complaints. Hence, other
cooling tower fan blade supplier M/S Aerotech were tried in Cooling Tower-1 by taking a
series of trials with different blade angle.

Procedure:
In CT-1, cell C fan was replaced with Aerotech supplied fans. Whole fan chimney area was
divided into 10 equal concentric annular points and nine annular spaces. Air velocity was
been measured at those nine points with the help of anemometer. Then the average velocity
and total air flow was calculated. Fans voltage, ampere reading was taken from concerned
substation.

Summary and Conclusions:

Cooling Tower-1 cell ‘J’ Paharpur fan flow was measured on 16th July, 2005. Total air flow at
19.5 pitch angle was around 11,98,931 CFM. Total power consumption was around 70.4 kW.
Cooling Tower-1 cell ‘C’ Aerotech fan flow was measured on 20th July, 2005. Total air flow at
12 pitch angle was around 13,05,577 CFM. Total power consumption was around 63.1 kW.
Total number of blades for each of the fans was 8.
There was a net increase of 8.9% air flow rate with Aerotech fans with 11.46% less power
consumption.
Material of Construction

Blades: Fibre Glass Reinforced Plastic Material using Polyester or Epoxy Resins

Hub Plates: Hot dipped galvanized Mild Steel or as per users specifications.

Blade Holding: cast Aluminum alloy Grade LM-6 or Cast Iron Grade FG 200

Seal Disk: FRP Plastic

Fasteners: SS-304

Center Bush: Cast Iron, Grade FG 200.

Axial flow FRP fans from Aerotech incorporate latest techniques in its manufacturing process
as well as designing that result in high efficiency of the fans. The efficiency difference with
respect to low efficiency fans is the cause of Energy Savings.
Design: Aerotech fans are designed by utilizing the latest aerodynamic profiles. The fan’s
tapered and twisted aerofoil design results in high efficiency.

Energy Efficient: More air with less power means less operating cost. Aerotech fans provide
20-40% power savings as compared to Metallic/GRP fans. Installations of these fans in newly
constructed equipment reduce initial equipment and operational costs.

Light Weight: Aerotech fans are light weight and allow easy handling and maintenance,
resulting in les down time. Further more the life of the gear box, motor and bearing is
extended.

Tough: Fibre glass reinforced plastic construction of Aerotech fans provides resilient,
dependable blades with high fatigue strength.
Low Noise: Aerotech’s unique aerofoil design reduces the operational fan noise level
considerably, as compared to conventional Metallic/GRP fans.

Corrosion and Erosion Resistance: Since Aerotech fans are made up of Fibre Glass
Reinforced Epoxy or polyester material, they are immune to corrosion. These fans have in-
built leading edge protection that prevents erosion from impinging water droplets. Even the
hub assemblies, consisting of M.S. hot dipped galvanized / SS plates with SS hardware and
C.I. Bushings, are corrosion resistant and provide years of trouble free service, even in
severely contaminated environment.

Durable: Aerotech FRP fans have a very high strength to weight ratio compared to
conventional materials such as Aluminium and steel. This ensures longer life and durability of
the fans.

Vibration Free: Aerotech fan blades are moment balanced for ease of installation. This also
ensures their direct interchangeability. The hub assemblies are statically / dynamically
balanced to ISO standards ensuring vibration free operation for years to come.

Recommendations / Forward Path:

Aerotech fans trial is satisfactory with energy savings of 11.49%, at the same time net
increase in air flow is 8.9%. On this result we should go for purchasing 18 fans from M/S
Aerotech by replacing the Paharpur fans. Purchasing may be done in two phases. Initially 8
fans can be bought for CT-1 and then in the second phase, remaining 10 fans can be
purchased for CT-2 based on the performance of the fans in CT-1.

Energy Awards

• Reliance, Jamnagar has bagged ICMA (Indian Chemical Manufacturers

Association) Award 2002 and 2004 for Excellence in Energy Conservation and
Energy Management.

• Reliance, Jamnagar has bagged award from BEE ( Ministry of Power) for
Excellence in Energy Conservation and Energy Management in 2003.
 • It has received award for "Excellence in Energy Management - 2002 , 2003, 2004
and 2005 by CII (Confederation of Indian Industries).

• Reliance, Jamnagar has bagged award in the Large projects for Exemplary
work in Energy Conservation by PCRA ( Petroleum Conservation Research
Association) in 2005.

• Reliance, Jamnagar received Oil & Gas Conservation Fortnight-2005 Award

from Ministry of Petroleum & Natural gas for First prize in minimum Steam
leaks. Steam leak rate in Jamnagar was as low as @ 0.044 Kgs/Ton of Steam

It has received award for "Excellence in Energy Conservation - 2003" by FGi

(Federation of Gujarat Industries)

Energy Conservation Plans and Targets

Reliance Jamnagar aims/plans to become the pace setter and world leader in respect of
Energy Conservation and Management in the refining sector. Reliance objectives are also
indicated in Energy Management Policy mentioned in Sheet-8 item 13 (e). The List of
Planned projects is shown under:

Sr. No. Project KTSRF/yr.

Increase in Preheat temperature from

241 DegC to 266 Deg C by Heat recovery
1 21.16
from VGO product stream in CDU1 &
CDU2.

Preheating CPP Deaerator make-up by

2 Condensate return from Sulphur & 12.37
Crude Units.

Heat recovery from New plate-frame

3 type Rich /lean Amine Exchanger in four 28
train of ATU.

Heat recovery from crude column

4 19.4
overhead vapor in CDU 1

Heat recovery from crude column

5 19.4
overhead vapor in CDU 2

Replacement of Aluminium blades of

6
fan with FRP blades.

a) Sulfur 1.9
b) Crude ( Remaining fans ) 1.43
c) FCC ( Remaining fans ) 1.43
d) Aromatics 2.18
 Replacement of existing MTF crude
7 1.84
charge pumps with lower capacity pump

Reduction of flaring by identifying the

8 source of flaring by installing meters in 10
flare line.

Reduction of radiation losses from

9 furnaces and boilers by application of 1.1
heat shield coating.

Steam loss reduction by steam trap

10 1
audit.

Reduction of LP steam consumption in

11 SWSU by routing Vacuum column O/H 5.42
condensor water directly to desalter.

Total 126.63

Ultimate Target
The ultimate target is to achieve lowest energy consumption per barrel of Crude oil feed stock
processed.
• To achieve Solomon International Energy Intensity Index of 55 or lower.
• To achieve Shell Corrected Energy and Loss Index of 80 or lower.

Environment & Safety

At Reliance Jamnagar, clean environment for sustainable development is of prime concern,

and is an important business objective, achieved by every employee’s contribution and
responsibility towards environmental performance.

Reliance Jamnagar is committed to the protection of environment. The design of state of the
art effluent treatment plant, low NOX burners in Furnaces and zero liquid effluent discharge
ensure the safety of the environment. Treated sewage, industrial effluent and stack emissions
are extensively monitored to ensure no harm is done to the environment. Reliance is
committed to transform the arid land in and around the complex into a lush green belt.
Following are the major improvements achieved during 2000-2006.

9 Reduction in Emission of CO2 (Tons/Kilotons of Crude processed) to 10.25.

9 Planting of 4.0 million trees in and around the complex has already been done till March
2005 which includes planting of 51,000 Nos of additional Trees during 2004-05.
Plantation of 35,000 trees in the direction of further enhancement of benefits of greening
like CO2 absorption & improved microclimate etc during last year.
9 Reduction of plastic cup consumption from 5.1 Lakhs cup (In 2000) per month to 3.2 Lakh
(2003) per month
9 Construction of landfill facility for the disposal of hazardous waste.
9 Incinerator plant is installed of 200Kg/Hr capacity for to incinerate the Hazardous Waste
like Oily Rags, Oily sludge & other oily contaminated material.
9 Reverse Osmosis (RO) installed of cap. 110 m3/hr.
9 Commitment to Safety is of paramount importance at Reliance. New work permit
procedures developed with the help of M/S Shell expertsare being consistently followed in
Jamnagar. The new procedure provide for more checks and responsibility according to
the hazard potential of each activity.
9 The British Safety Council conducted a Safety and Health Management audit at
Jamnagar and awarded the highest Five Star rating to the site in 2003.
The Jamnagar refinery complex is certified as ISO-14000 company conforming the
Environmental Management System. State pollution control board has given rebate in the
water Cess consecutively for the past three years.

Commitment to Safety is of paramount importance at Reliance. New work permit procedures

developed are being consistently followed in Jamnagar. The new procedure provide for more
checks and responsibility according to the hazard potential of each activity.

The British Safety Council conducted a Safety and Health Management audit at
Jamnagar and awarded the highest Five Star rating to the site.
(1) World’s Largest Grass Root Refinery:

(2) World’s Largest Grass Root Crude Distillation Unit

3) World’s Largest FCC Unit

(4) World’s Largest Delayed Coker Unit

(5) World’s Largest Para Xylene Production Units at single location

(6) Highly Efficient Co-generation Captive Power Plant

(7) Multiple Effect Evaporator Desalination Units

(8) India’s Largest All Weather Petroleum Terminal

(9) India’s first Automated Rail Gantry in Single Spur

(10) Crude Receipt by Two SPMs (Single Point Mooring)

(11) Refinery Green Belt is Spread over 1500 Acres

(12) Green Belt has more than 3 Million Trees

Installation of LCGO reboiler in parallel with the existing MP steam reboiler in coker
resulting in reduction of MP steam.

Installation of Heat exchanger in Crude unit for heat recovery from HK.