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Disclaimer
Any statement, opinion, prediction, comment, or observation made in this
presentation/publication are those of the presenter/author only and in no conditionshould be construed necessarily representing the policy and intent of Reliance
Industries Ltd. (RIL).
The information presented herein are of the presenter/authors 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
presenters/authors 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
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Reliance Industries Ltd.
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Index
Fundamentals
Crude flexibility
Petrochemical Integration
Conclusion
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Refinery competitiveness: Fundamentals
2 mantras for refinery competitiveness
Minimize feed costs
Low crude cost crude flexibility : Sourcing
: Processing
: Quality
Low opex
Maximize product revenues
High value product petrochemical integration
Distillates = Jet + diesel + gasoline
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Crude flexibility: Sourcing
Max crude sourcing flexibility
Quantity
Process 1358 kb/d of crude (FY15)
Source crude globally
Quality
Refine 144 crude grades from 1999 (16 years)
Virtually any crude grade can be refined
No constraints on crude properties
Refine 13 new crude grades (FY15)
Refine new crude grades Jamnagar is the destination of choice for novel crude
Eg. Basra heavy (FY15)
Process any distressed crude cargo
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Crude flexibility: Processing
Max crude processing flexibility
Dilution - 1358 kb/d of crude, large pool for dilution
- VLCC = 60 kb/d or 4.4% of crude feed
- Suez Max = 45 kb/d or 3.3% of crude feed
- Afra Max = 30 kb/d or 2.2% of crude feed
- Refine any crude grade by dilution principle
Sequencing & Scheduling - Sequence optimal arrivals of crude grades
- Crude scheduling to enable optimal blending
- GeCOS system (Shell)
Blending - Process crude grades with wide range of qualities
- Blend to narrow crude feed window
- Minimal variation seen by refinery CDU/VDU
- TIS / OMS system (Schneider)
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Crude flexibility: Quality
Max crude quality flexibility
API = From 130API to 560API
- Peregrino (Brazil) = 13.4API
- Ras Gas condensate = 560API
Sour = From 0 to 6.7 wt%
- Coban (Guatemala), S = 6.7 %
Acidic = From 0 to 5.3 TAN
- Olende (Gabon), TAN = 5.3 mg KOH
Metals = From 0 to 450 ppm Ni + V
- Napo (Equador), Ni + V = 450 ppm
Synthetic crudes = From bitumen upgraders
- Hamaca (Venezuela)
- Cold Lake (Canada)
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Petrochemical integration: Value Addition
Max value addition to petrochemicals
Product $/t % of Crude
Petrochemicals:
PX 825-845 198
Propylene 760-780 183
Ethylene 740-760 178
Distillates:
Jet 575-585 138
Diesel 555-565 133
Gasoline 545-555 131
Others
Naphtha 470 112
LPG 460 110
Fuel gas 440 104
Crude 420 Base
Basis = Crude @ $60/bbl
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Petrochemicals integration: Jamnagar refinery
Maximize margins
Propylene : 2 mmt/yr propylene @ 3% of crude
: 2 FCC @ 420 kb/d
: 100% captive consumption to PP
: Advantage feed = Hydrotreated VGO to FCC
Aromatics : 5.45 mmt/yr Aromatics @ 8.1% of crude
: 2 Platformer @ 190 kb/d
: 4.2 mmt/yr PX
: Advantage feed = Reformate
ROG Cracker : 1.8 mmt/yr ethylene derivatives
: 2.7% of crude
: Advantage feed = Refinery off gas (ROG)
: Gasification enabled = Swap SNG for Cracker feed
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Petrochemicals: Propylene
Value addition to propylene + PP
FCC : 2 units, combined capacity = 420 kb/d
: Worlds largest FCC (UOP)
: Moderate severity, >10% C3= yields
: 2 mmt/yr of propylene
PRU : 3 units
: C3 splitter design with heat pump (UOP)
PP : 6 PP lines, 4 275 kt/yr + 2 450 kt/yr
: Combined capacity = 2 mmt/yr PP
: Gas phase bulk polymer (Dow)
: Worlds largest PP complex
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Petrochemicals: Aromatics
Worlds largest PX complex
Aromatics DTA SEZ/PX-4 Total
CCR reformer, kb/d 90 100 190
PX, mmt/yr 1.9 2.3 4.2
OX, mmt/yr 0.3 0 0.3
Benzene, mmt/yr 0.4 0.55 0.95
Total Aromatics, mmt/yr 2.6 2.85 5.45
Process Selective adsorption Crystallization
Parex / Isom trains 3 / 3 0 / 1
Crystallizers / Centrifuges 0 3
Trans alkylation 2 1Extractive distillation 1 1
Licensor UOP BP / Lummus
Status Operating Construction
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Petrochemicals: Integrated Aromatics
Global #2 in polyester
Crude to naphtha to PX @ Jamnagar refinery
PX to PTA to PET @ Dahej
PX to PTAto Polyester @ Silvassa + Hazira
PTA to Polyester @ Silvassa Integrated polyester value chain
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Petrochemicals: ROG Cracker
Worlds largest ROG Cracker
Feed : Extract C2
+ C2
= from refinery offgas (ROG)
: Rich feed = 27% C2= in feed
: Substitute C2 + C2= with SNG
: Syngas from petcoke gasification produces SNG
: SNG substitutes ROG as heater fuel
Product : 1.5 mmt/yr ethylene
: Coproducts = Propylene + H2
: 730 kt/yr MEG
: 400 kt/yr LDPE
: 650 kt/yr LLDPE: 1.8 mmt/yr of ethylene derivatives
: MEG = Link in the polyester value chain
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Integration of Refinery + Petrochemicals + Gasification
Integration
Refinery Gasification
PX-4
C2complex
MEG
LDPE
LLDPE
Syngas/cogen fuel
C2+ C2=
H2
Crude Petcoke
H2
SNG
Syngas/new htr fuel Syngas/cogen fuel
PX
BenzeneReformate
Existing
New
Syngas/cogen fuel
Return
Future Chemicals
Olefins
Aromatics
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Innovate or perish
Conclusion
Competitive refining
Process lowest cost crude feed
Generate highest value petrochemical products
Integrated refinery + petrochemicals
PP from VGO via FCCs
PX + benzene from naphtha via Platformers
Ethylene from ROG Cracker
Low cost utilities
Recover C2 + C2= to feed ROG Cracker; substitute with SNG Cogen fuel from gasification for power + steam
H2 from gasification
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