Thank You

The Jamnagar Gasification Project

by

Dr. Partha Maitra

Reliance Industries, India

13 - 16th 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 world’s largest refinery @ Jamnagar

• Owns 25% of world’s 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

World’s 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 : 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.

5

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

6

Refinery – gasification integration

Integrate refinery + gasification

Refinery Gasification

Existing

New

Petcoke

Petcoke import

Crude

H2

SNG

Syngas/cogen fuel

LNG import

Syngas/htr fuel

7

Petchem – gasification integration

Integrate petchem + gasification @ Jamnagar

Refinery Gasification

PX-4

C2 complex

MEG

LDPE

LLDPE/HDPE

Syngas/cogen fuel

C2 + C2=

H2

Crude Petcoke

H2

SNG

Syngas/htr fuel Syngas/cogen fuel

PX

BenzeneReformate

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

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

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, 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

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

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

Boost refinery + petrochem performance

Gasification : Fuel + H2 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

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

13

Energy flow diagram - schematic

Gasification product slate

Gasifier100

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

12.412.4

H2

Loss

6.1

125.8

Loss0.9

Petcoke COCO reco

SNG

ShiftPSA

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 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

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 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

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