Gasification Technologies Conference 2013

The Jamnagar Gasification Project

by
Dr. Partha Maitra
Thank You
Reliance Industries, India

13 - 16th October, 2013 Colorado Springs, USA

 Index

 Reliance

 Jamnagar refinery

 Integration

 Gasification

 Conclusion

2
 Reliance: An introduction

Performance; FY13 $bn • Operates the world’s largest refinery @ Jamnagar

Revenue/turnover 68.4
• Owns 25% of world’s complex refining capacity
Exports 44.1
• Among top 10 independent refiners
Earnings, EBDIT 7.1
• Flexible in crude sourcing + product exports
Cash profit 5.6
• Generate higher margin per barrel, w.r.t peers
Net profit 3.9
• Low cost producer of refinery products
Net worth 32.7 • #1 in polyester, in the world

Assets 58.0 • #107 in Fortune Global 500 (2013)

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

 Global Indian company 3

 Jamnagar refinery

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 : C2 complex: 1650 kt/yr C2=, + 150 kt/yr C3=
: Recover ethane + ethylene in RFG
Crack ethane to ethylene + C2 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.

 World’s largest refinery + petrochemical complex 4

 Gasification: Profile

● Configuration : World’s largest w/ 10 gasifiers

● Feed : Petcoke, w/ coal blend flexibility
● Output : 8.0 bcm/yr syngas, NG equiv; 2.6 million Nm3/hr syngas
● Product : Cogen fuel : Produce power + steam
H2 : Eliminate on-purpose H2
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

 World’s largest gasification complex 5

 Refinery – gasification integration

Petcoke import
LNG import

Petcoke
Crude Refinery Gasification

H2

SNG

Syngas/cogen fuel

Syngas/htr fuel

Existing

New

 Integrate refinery + gasification 6

 Petchem – gasification integration

C2 + C2= MEG

H2 C2 complex LDPE

LLDPE/HDPE

Syngas/cogen fuel

Crude Petcoke
H2
CO Acetic
Gasification Acetic
Refinery SNG acid
acid
Syngas/cogen fuel

Syngas/htr fuel Syngas/cogen fuel

Return
PX
Reformate PX-4
Benzene

Existing

New

 Integrate petchem + gasification @ Jamnagar 7

 Demand profile

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
H2 H2 t/d
Capacity 1440 8 stm. methane reformer
Existing demand 1175 On-purpose
New project (400) H2 from C2 complex
Total 775 H2 from syngas

 Satisfy Jamnagar utility demand w/ syngas from gasification 8

 Driver

Petcoke : Lowest value refinery product

: Bottomless refinery w/petcoke gasification

Syngas : 100% captive consumption @ Jamnagar

: Consumption = Cogen fuel, SNG/syngas as htr fuel, H2 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/ C2 + C2= in RFG, as advantage petchem feed

 Boost refinery margin + add value w/ petrochem 9

 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 10

 Product profile

Syngas bcm/yr % Routing

Cogen fuel 5.05 63 Existing + new GTG + HRSG
H2 1.3 16 Existing H2 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

Gasification : Fuel + H2 for refinery

: Feed + fuel for petchem

 Boost refinery + petrochem performance 11

 Product summary

Cogen fuel : Repower existing + new GTG + HRSG for captive power + steam
: Power + steam = 2505 MW; existing =1505 MW, new = 1000MW
H2 : Supply H2 for clean fuels, equiv. to 775 t/d H2
: Shut down existing H2 plants
SNG : Recover C2+C2= to feed new Cracker in C2 complex
: Substitute C2+C2= 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 : NH3 recovery
: CO2 capture
: Metals recovery

 Optimized gasification product slate 12

 Energy flow diagram - schematic

4.9 Syngas/new
htr fuel

53.6 54.6
Syngas/
cogen fuel
1.0

125.8 2.7
100 1.7
Petcoke Gasifier CO reco CO

25.8

Loss 5.0 10.6 SNG/existing

SNG htr fuel
6.5
0.9
Loss

25.0
Shift 12.4
12.4
8.8 PSA H2

Parasitic 6.1

Loss

 Gasification product slate 13

 Configuration

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

 Optimized scope 14
 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 15

 Mega project

# Gasification Associated Total

PFD 5x9 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
Source: Fluor

Detailed engineering
Task force : 400, to peak at 600
Man hour : 1.6 million
Location : Fluor, Houston & Delhi

 Major EPC effort 16

 Capex

Gasification %
License, engineering, consultancy 5
Equipment + packages 48
Bulk material 16
Construction 14
Others(1) 7
Financing 5
Contingency 5
Total 100
Note 1: Others – freight, startup + commission, duties + taxes, preoperative, insurance, inspection

Jamnagar gasification = Projected at 75-83% of USGC capex

 Competitive capex 17
 Status

Project kickoff May’12

PFD review Complete
P&ID review + HAZOP Complete
30% model review Complete
Equipment/package awards 90% complete (end Sep’13)

Detailed engineering 35% complete (end Sep’13)

Construction Commenced in Apr’13

 Target startup = mid 2015 18

 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 H2 from syngas, for refinery clean fuels
− Utilize SNG + syngas as fuel for process heaters
● Petchem feed:
− Recover C2 + C2= 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
19
Thank
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