Thank You

UPDATE OF PETCOKE GASIFICATION PROJECT

AT JAMNAGAR, INDIA

THOMAS MATHEW AND NITIN KARVEKAR

6th December 2017 Reliance Industries Ltd New Delhi
 Disclaimer
Any statement, opinion, prediction, comment, or observation made in this
presentation/publication are those of the presenter/author only and in no condition
should be construed necessarily representing the policy and intent of Reliance
Industries Ltd. (RIL).

The information presented herein are of the presenter/author’s own and in no way RIL
attracts any liability for any inconsistency or irregularity in terms of the accuracy
completeness, veracity, or truth of the content of the presentation/publication. In
addition, RIL shall not be liable for any copyright infringement and misrepresentation for
the presented content as the content is presumed in good faith to be a creation of
presenter’s/author’s own mind.

The scope of this presentation/publication is strictly for knowledge sharing purposes and
not necessarily to provide any advice or recommendation to the audience/readers. Any
endorsement, recommendation, suggestion, or advice made by the presenter/author
shall be in his personal capacity and not in professional capacity as an employee of RIL.
Any person acting on such endorsement, recommendation, suggestion, or advice will
himself/herself be responsible for any injury/damage.

© Reliance Industries Ltd.

2
Index
• Reliance & Jamnagar refinery

• Petcoke gasification

• Base syngas utilization

• Project details and Status

• Technology Challenges &

Operational Preparedeness

• Future syngas utilization

• Conclusion

3
 Reliance – An Introduction

Growth Journey
 1958: Reliance Commercial Corporation – Trading House
 1966: Naroda Textile Units – Vimal Fabric
 1977: Reliance goes Public – Reliance IPO
 1982-88: Patalganga Complex – POY/ PSF/ PTA/ LAB/ PX
 1991-92: Hazira Phase I – MEG/ PVC/ VCM/
 1997-97: Hazira Phase II- PTA 1,2/ PFY/ PSF/ PET/ PP/ Naphtha Cracker
 1999-00: Jamnagar DTA Refinery (J1)
 2000-01: Reliance Info-comm
 2005-06: Reliance Retail
 2008-09: Jamnagar SEZ Refinery (J2)/ KGD6 Gas Production
 2016-17: J3 Project Implementation: Gasification Project & Jio 4G

 Make-in-India & Digital India 4

Reliance: An Introduction
Reliance Industries Ltd, India
• #1 company in India, in private sector
• Global rankings, (Fortune 2017)

#203 in revenues;#110 in profits

• Performance, FY ’17 $bn

Revenue 50.9
Earnings, EBDIT 8.6
Market capitalization 90
Net worth 44.5
• Growth, CAGR (1) %
Earnings 26.7
Market capitalization 31.5
Net worth(NW) 13.9
• Returns (adjusted) (2) %
ROCE 25.4
RONW 16.8

Note: (1)CAGR =compounded annual growth rate since IPO in 1977

(2) Adjusted for work in progress

 Indian company, with a global footprint

5
Jamnagar Refinery : A profile
Jamnagar refinery
• Largest refinery
 Crude processed, kb/d 1380
 World rank,# 1
• Superlative performance
 Complexity Index 12.7
 Energy Intensity Index 64
 Availability,% ~97
• Integrated complex
 Petrochemicals, %of crude 14.5
 Utilities & power, % captive 100

 Ports & terminal 5 SPM + 5 berth jetty

• Global exports
 By revenues,% 51
 By volume, % 56
• Margins
GRM,FY’17 $/bbl
Jamnagar 11.0
USGC/WTI 8.7
Singapore/Dubai 5.8
Rotterdam/Brent 5.3
Note: GRM = Gross refining margin

 Arguably the best refinery in the world 6

Jamnagar Gasification

Scope :

Crude oil Fuels

Refinery Diesel + jet + gasoline LNG Import
4 trains
1380 kb/d Petrochemicals

Vac resid
Coker
Fuels
2 x 8 drums Syngas @10 GWth
340 kb/d
23.2 mmscm/d NG equiv.

Pet coke
Petcoke = 9.1% of crude feed Petcoke
6.3 mmt/yr Gasification
Petcoke import 10 gasifiers
4.0 mmt/yr

Sulphur

2000 t/d
 Gasify petcoke to syngas, for 100% Jamnagar consumption
7
 SCOPE: Gasification Configuration: BFD

SRU/TGTU SFU Sulfur

HHP steam
export
CO2

Acid gas
Open Art
Units PSA H2
HHP steam
Syngas
LTGC
O2
ASU Gasification AGR Methanation SNG
Shift & GC

water
Sour
CO
recovery Chemic
Petcoke
SWS
als
CPP Power

OSBL Offsite

Dotted line indicates future vistas

8
 Gasification Configuration:

HHP
10steam
Gasifiers
Config  4export
in DTA refinery; 6 in SEZ refinery
 Modular design, 2 gasifiers /modules

 1,150 MWth gasifier largest in the world

Feed  100% petcoke feed, ~2,900 tpd per gasifier
 65% petcoke + 35% coal feed blend flexibility

 5 ASU, 1 ASU/ gasifier module

ASU  5,250 t/d 99% O2

 2.3 mmscmd NG equiv / gasifier (272 kNm3/hr)

Product  Repower 1,300 MW CPP with syngas and 1,700 tph of steam
 1,160 t/d H2, 2-4 mmscmd SNGDotted
(balancing product)
line indicates future vistas

9
Project : Scope
Engineering: #

PFD 115

P & ID 1700

Equipment: #
Equipment 2920
Piping isometrics 44,000
Materials: Quantity
Concrete, million cum 1.1
Structural steel, kt 210
Piping, million in m 14
Electrical cable, km 3900
Instrumentation cable, km 6500
Construction: #
Construction workers, peak >1,00,000
Cranes, peak >1700

 Flagship gasification project of the world

10
 CURRENT STATUS

• World’s largest ASU 1 unit commissioned

successfully and operational

• First Gasifier unit refractory drying and alkali

boil out completed

• All utilities are operational

• AGR unit commissioning under progress

 No compromise on safety 11
 CURRENT STATUS

 No compromise on safety 12
 CURRENT STATUS

 No compromise on safety 13
 CURRENT STATUS

 No compromise on safety 14
 CURRENT STATUS

 No compromise on safety 15
 Technology Challenges
Operational Challenges: Successful Gasifier operation depends on

 Consistent quality of feed-stock

 Proper blend of fluxant

 Slurry properties like stability, strength, and viscosity (Flowability / Pumpability)

 Life of slurry mixer (burner)

 Gasifier design to provide right volume and temperature

 Slag flow characteristics

 Refractory Life

 No compromise on safety 16
 Technology Challenges

Process Safety

 Handling of Toxic chemicals - Hydrogen Sulphide (TLV 1ppm), Syngas- Carbon

Monoxide (TLV – 25 ppm)

 Handling of Flammable & Explosion Hazards- H2, pure Oxygen, methanol,

 Handling of solids - Dust explosion Hazards- Petcoke, coal,

 Conservative designs – compliance to international standards (AIGA/ EIGA)

 Developed standards for handling toxic chemicals

 Detail Consequence Analysis studies of complete complex and action plan

 No compromise on safety 17
 Operational Preparedness
Operational Preparedness:
 Study on effect of fluxant to feed ratio on ash viscosity with temperature – Optimized
fluxant to feed ratio

 Study on slurry preparation using optimized fluxant to feed ratio – Optimized slurry
stability, strength, and viscosity

 Study using optimized slurry for understanding the reaction kinetics using equipment in
entrained flow environment

 Validating scaled up Gasifier design using kinetics and CFD modeling

 A detail work plan prepared. Various teams comprising members from different areas
prepared to handle each concerned area.

 Flawless and smooth Start-up

18
 Operational Preparedness

Operational Preparedness:
Tie up with renowned research institutes / Universities:

• Working with Penn State Universities, Micro beam Technology, USA. Planning to
collaborate with NETL, Frieberg University, Germany.
• Generate the property data for actual feed stocks and develop correlations for
predicting properties
• Generate kinetic data for development of model
• Develop CFD models
Extensive Dynamic simulation study of:
• Gasification module to validate control philosophy provided by licensor
• Control system for all units in Gasification complex individually and integrated way
• Control system of Gasification complex with rest of the Jamnagar complex
• Extensive use of OTS for operational training

 Flawless and smooth Start-up 19

Gasification: Future Enhancements
NH3 Recover NH3 @ 140 kt/yr from sour water
43% from gasification + 57% from refinery
Convert N, a crude contaminant, into an opportunity
Substitute imports, into India
Urea Exploit pure CO2 from gasification shift
Add CO2 to NH3, recovered + imports
Boost fertilizer supply + food security of India
V Recover vanadium(V) @ 9.5 kt/yr from gasification slag
Recover Ni @ 2.0 kt/yr as co product
Convert V, a crude contaminant into a metals opportunity
Global #1 in V, a micro alloy for high strength steel
Ethanol Exploit syngas for synthetic ethanol
Use biochemical reaction kinetics
Blend ethanol into crude derived gasoline
Stretch gasoline without crude increase
APC + RTO Develop integrated gasification model
Model scope = 10 gasifiers + syngas headers
APC = Advance process control
RTO = Real time optimization using ROMeo software
Enhance gasification performance AGR – Methanol Wash column
 Enhance gasification economics
20
Future Syngas Utilization
Gasification Syngas quality @ H2/CO = 0.62

Syngas price @ 40% discount to LNG derived syngas

Base syngas utilization = H2 + plant fuel

Future syngas utilization = Oxygenated chemicals

CO Recover CO from low H2/CO syngas

Exploit low cost CO feed for acetic acid + ethylene glycol

Derive acetyl chemicals from acetic acid

Acetates + VAM + VAE + PVacetate + PValcohol

Ethylene glycol, via unconv.process from CO

Acrylic acid ,via unconv. process from CO, in future
Syngas Target chemicals, requiring low H2/CO syngas as feed

Oxo–alcohols + DME + MMA/ PMMA

Blend DME into crude derived LPG

Methanol and its derivatives

CO2 CO2 capture ready plant

Identify technology for CO2 utilization/sequestration

 Maximize value addition with syngas to chemicals

21
 Global landmark in Gasification

Path-breaker for Indian Energy Sector

22
Thank
ThankYou
You