Reliance Jamnagar Complex

CII

National Award
f or
“Excellence in Energy Management – 2008”
By
H. V. LOD HIA – Team Lea der
R. R. K AMDI
S. KHA NDELWA L

August 22-23, 2 008

Content

• Overview of Jamnagar Refinery

• Energy Conservation efforts

• Comparison with Global Benchmark

• ENCON Projects

• Monitoring & Reporting formats

• Environment Concerns

1
Reliance Jamnagar … a recap
Reliance Industries Limited - Jamnagar is a fully integrated
manufacturing complex comprising of
- Refinery complex
- Petrochemical complex
- Power generation complex
- Port & terminal complex along with the associated
pipeline network.
The refinery is the world’s largest grass root refinery.
RIL is also setting up another export refinery beside the
existing one at Jamnagar which will make it largest refinery
complex in the World.

Reliance Jamnagar Complex Overview

• 650,000 BPSD Refining capacity

• Two trains of Crude Distillation Unit, V DUs, HTs
• World’s largest FCCU
• World’s largest DCU with 8 Coke drums
• World’s largest Aromatics complex with largest
Para-xylene plant
• A Captive Power Plant with an installed capacity of
450 MW through GTs and STGs
• Technologies are from world leaders like UOP, Foster
Wheeler Inc., Linde A G, Black & Veatch Pritchard,
Dow etc.
• Also called as Greenfield Refinery

2
Reliance Jamnagar Process Overview
LPG
LPG
LPG Merox
Fuel Gas Hydrogen PC Naphtha
Hydrogen
Manufacturing
Benz en e p
Unit
R Gasoline
OX
Naphtha Heav y Naphtha O
Splitter HNHT Plat forme r Aromati cs PX D Naphtha
U
C SKO / AT F
ATF / S KO T
Kero sen e Kero M erox PP HSD
Unsat LPG PP
PRU
CDU / VD U Merox B
Dies el LPG
L Fuel Oi l /
Dies el HT HSD E GT Fue l
CRUDE N
D Benz en e
VGO Gasoline I
Gasoline N OX
VGOHT FCC
Merox G
PX

SHP / TAM E TAME

Delayed B Coke
Vacuum R es idue Naphtha
Coking LNHT Naphtha L
Unit O
Marine / Oi l C Sulfur
Coke
Move ment & K
Storage
ATU Acid Gas PP
Sulfur
Power & SWS Gas SRU
Utilities
SWS

In tegrated refi n ery , addi ng valu e to sh are h ol ders.

Jamnagar SEZ Export Refinery Overview

• 580,000 barrels per day stand alone refinery with

secondary units like FCCU, DCU, HTs, Alkylation etc.
• 900,000 tonnes per annum Polypropylene plant

• Investments of US$ 6bn in an SEZ at Jamnagar

• Capable of producing Clean Fuels for the future

• On fast track implementation, expected to be completed

by Dec’08.

Making Jamn agar as Refini ng hu b of th e worl d

3
Jamnagar : Refining Hub of the World

BPSD
RIL Group, India 1,230,000

Paraguana Refining, Venezuela 940,000

SK Corp, So uth Korea 817,000

Relian ce Ind ust ries Ltd, Ind ia 650,00 0

LG -Caltex, South Korea 650,000

Exxon Mobil, Singapore 605,000

RPL's Propo sed R efi nery 580,00 0

Exxon Mobil, Baytown, USA 557,000

S-Oil Corp, So uth Korea 520,000

Hovensa LLC, Virgin Islands 495,000

Exxon Mobil, Baton Rouge, USA 493,500

Shell Eastern, Singapore 458,000

0 200,000 400,000 600,000 800,000 1,000,000

So urce: Oil and Gas Jo urnal

RIL – RPL com bi n e to be th e l argest refin ery com pl ex in th e worl d

RIL Refinery – Way Ahead of Competition

C o m p l e x i t y( I n d e x )

Reliance
La rge & hi gh
ma rgi n Econ omy
Haldia of Sca l e
MRL & Pani pat
HPC L & CRL
MRP L
BPCL
Vizag Koyali
BRP L
Bara uni Mat hura
2

Digboi Sma ll & l ow

4

ma rgi n
6
8

5 10 15 20 25 30 35
Capacity ( MM TP A)

Most complex ref inery in the region

4
En-Con Efforts in last 3 yrs

En-Con Efforts in last 3 years

Pay back
I nv estment Savings
Perio d
Sr. No. of Projects
Year
No I mplemented
Rs.
Rs. La khs Month s
Lakhs/ Annum

1 2007 -08 3 638 2484 3

2 2006-0 7 3 1860 3579 6

3 200 5-06 4 860 1781 6

To tal 10 3358 7844 5

En-Con Projects in the Year 2007 - 08

En-Con Projects implemented in the Year 2007-08

Payback
Investment Savings
Period
Sr.
Project I mplemente d
No
Rs.
Rs. La khs Month s
Lakhs/ Annum

Heat recove ry from New P late-F rame type

1 Rich /lean Am ine Heat Exchange r in 2 192 110 0 2
train s of ATU by replacing Shell & Tu be HE

Increa se in c rude preheat tempe rature by

20° C in Crude D istiller -1 by Heat recov ery
2 441 1290 4
from h ot VG OHT product stre am (P inch
Technology)

Hydrotre aters st ripper HP stea m

3 4.53 94 1
replacem ent by MP stea m

To tal 637.5 3 2484 3

5
Specific Energy Consumption

Specific Energy Consumption

Sr.
Yea r En ergy Con su mpti on (Kbt u /bbl /NRGF )
No
1 2000- 01 48.7
2 2001-02 47.2
3 2002-03 46.7
4 2003-04 45.8
5 2004-05 42.6
6 2005-06 39.6
7 2006-07 36.3

8 2007-08 34.0

Shell Benchmarking Performance

En ergy Perf orma n ce In di ca t or - CEL
220
Corrected Energy and Loss Index - 85.4 (2007)
200 Reli ance, Jamnagar Refin er y
continuous to be the Pacesetter
CEL 95.2 in 200 0
180 CEL 94.4 in 200 1
CEL 88.7 in 20 02
CEL 95.6 in 20 00
CEL 87.6 in 200 3
.

160 CEL 93.9 in 20 01

CEL 86.9 in 2004
CEL 88.7 in 20 02
Index

CEL 89.5 in 20 05
CEL 87.6 in 20 03
140 CEL 86.9 in 2006
CEL 86.9 in 20 04
CEL 85.4 in 20 07
CEL 89.5 in 20 05
CEL 86.9 in 2006
120

100

80
3

6
7

9
2

4
5

4
6

0
1

1
1
1
1

1
1

2
2

2
2
2
2
2
2
2
3

3
3
3
3
3

4
0
1
2
3
4
5

7
8

0
1
2
3
4
5
6
7
8
9
0

2
3

5
6
7
8
9

Performa nce of other Interna tional Re fineries (Hi gh CEL )

M
A
J

CEL Index SBR SBR

6
Solomon Benchmarking Performance

Energy Intensity Index (EII - Solomon) - Trend

74 72
70 69
66
EII

58

50
2002 2004 2006

Year

Performance Summary : Solomon Benchmarking 2006

Asia/Pacific Excluding Japan
RIL Cash Operating Expense, U S cents/UEDC
35.6 31.5 R 79.8

Energy Intensity Index

69 66.7 R 131. 1
Maintenanc e Index , U S $/EDC
6.6 R 7.3 48.5

Personnel Index , W ork Hours/100 EDC

127.4 60.4 R 471.1

Refinery Utilizati on
91.5 95.9 R 60.8
Mechanical Availability
95.7 98.1 R 91.7
Net Cash Margin, U S $/bbl
11.3 R 10.9 -0.98

Return on Investment, %
28.8 R 25.5 -0.29

7
RIL JAMNAGAR Road Map to achieve Best

IMPROVEMENT STRATEGIES

Pot ential Performance

2. Application of
"Best Practices"
Performance

4. Benchmarking
maintains stimulus for
continuous improvement

3. Benchmarking helps
to measure success in
GAP closing the gap

Current Performance
1. Benchmarking identifies
opportunities for improvement

Time

Reliance Jamnagar Complex

Innovative En-Con Projects

8
 En-Con Projects at RIL, Jamnagar
1. Reduction in steam consumption in stripper
reboilers Of Amine Treating units (ATU).
– AT Us funct ion is t o rem ov e H2S & CO2 fr om FG or LPG & t o
reg enerat e th e rich am ine t o lean am ine in stripper
– In or iginal design Lean am ine fr om stripper bott om r outed
thr ough a Sh ell & Tube HE t o heat rich am ine feed t o stripper
– Appr oach tem p. in Shell & Tube HE wa s 48 oC
– Replacem ent of S & T HE with Plate & Fram e HE carried out
t o in crea se th e h eat r ecov ery fr om h ot lean am ine int o the rich
am ine feed t o stripper.
– Appr oach tem p. in New Plat e & Fram e HE is 27 oC.
– Steam con sum ption in str ipper reboiler reduced due t o incr ea se
in heat recov ery , redu cti on in GHG emi ssi on

En-Con Projects at RIL, Jamnagar

Acid Gas to
Knock-Out Drum

Rich Amine to Amine Stripper

Amine
Amine
Stripper
Stripper

LP Ste am fr om
CPP

Lean Amine from Amine Stripper Amine stripper

Reboilers (2 Nos )
Lean Amine Pump
131 0C

104 0C
Rich / Lean Amine Heat
1310C Exchanger
(Shell & Tube type)
83 0C Rich / Lean Amine Heat
Exchanger
59 0C (Plate & Frame type)

Rich Amine from

Rich Flash Drum 107 0C

86 0C

59 0C

Lean Amine to Lean Amine cooler Phot ograph

Stripper reb oiler i n A mi ne Treating U nitwit h new Pl ate & Frame Heat Ex changer

9
En-Con Projects at RIL, Jamnagar

Phot ograph: Plate & Fram e He at Exch anger in ATU

En-Con Projects at RIL, Jamnagar

Project Know-how
– Project activity is the result of in-house R & D and
involved a process simulation to make changes.
– Project has been implemented in three Units.
– The modification was referred to technology provider
and was vetted by them before implementation
– Investment : Rs. 339 Lacs in four trains
– Reduction of 12 MT/Hr of LP steam per train
costing Rs. 2198 Lacs per annum in four trains
– Estimated annual CERs are 96867 (CDM Project)

10
 En-Con Projects at RIL, Jamnagar
2. Increase in Crude Preheat Temperature from 247 oC t o
267 oC by Heat recovery from VGO Product stream in
Crude Distiller Unit (CDU)-1 using Pinch Technology
– The Crude Preheat train is div ided into 3 sections which are Cold
Pr eheat Train, Warm Preheat Train and Hot Preheat Train
– In cold preheat train, Crude fr om BL at 30 oC is preheated t o 145
o C by h ot Naphtha PA*, HK PA, Diesel PA, LK & VR product

stream s
– In warm preheat train, Crude is preheated from 1 45 oC t o 17 0 oC
by hot HK PA , Diesel PA, HAGO PA, HVGO PA and VR pr oduct
– In hot preheat train, Crude is preheated from 170 oC t o 247 oC by
hot HVGO PA, HAGO PA, Slope wax PA & VR stream s.
– Crude finally enters Crude Heaters at ~ 247 o C for further
preheating
*PA: Pump a round

En-Con Projects at RIL, Jamnagar

– Crude preheat trains optim ization was carried out using the
Pinch Techn ology t o exploit potential av ailable of integrating
CDU with other units
– Modification s have been im plem ented in the hot preheat
exchanger train of CDU-1 which inv olv ed Hot VGO stream r outing
fr om VGOHT-1 t o CDU-1
– Additional exchangers were added a s 3 rd parallel Hot preheat train
t o extract heat av ailable in Hot VGO stream for preheating crude
– This has increased the inlet tem perature of Crude Heaters by 20
o C (fr om 247 oC t o 267 oC ) for the throughput of 325 KBPSD

– This has reduced the firing in the F-01 and F-51 furnaces by 25
Gcal /Hr com bined which is equiv alent to sav ing of 20,000T /yr
of fuel oil
– The cost of im plem entation of this pr oject was Rs.44.10 Million

11
En-Con Projects at RIL, Jamnagar

En-Con Projects at RIL, Jamnagar

12
 Carbon Emission Reduction Projects at
RIL, Jamnagar
Sr. Annua l CER
Project Activity D escription Remar ks
No. (MT of CO 2)

Regist er ed wi th
1 Rerou tin g of Sat Gas Con St ripp er of f gas es dir ec tl y to 36690 UNFC C C & veri fi ed
Primar y absorb er f eed by passin g HP receiver in C DU I/II
two ti mes

Redu ctio n in st eam con sum ptio n in str ipp er reboil er of

2 ATU by rep lacin g Shell & Tube HE w ith P lat e & Frame 96867 Validation ov er
HE.
Redu ctio n in st eam d emand fo r Napht ha split ter rebo iler
3 23174 Validation ov er
in Coker thro ugh inno vati ve pr ocess in tegrat ion.

4 Main Flare Gas Recover y 45,000 PDD Pr epar ed

5 Coker Blow-do wn Ven t Gas reco very 45,000 PDD Pr epar ed

6 Fuel G as firing in G as Turbines 70,000 Estimate d CE R

7 Routing of rich amine flash gases in V GO HT to ATU sat gas 17,000 Estimate d CE R
absorbe rs

Re-routing of LPG Merox gases to co mb ustion air in CDU -2 (t o

8 18,000 Estimate d CE R
enable dis posal of VDU off gases in f urnaces)

9 Inlet air fo gging in Gas T urbines in CPP 94,000 Estimate d CE R

Tota l 4,45,7 31

En-Con Team

13
Monitoring and Reporting Practices

Para meter Monitori ng/Re porti ng Freque ncy

Fuel & Loss D aily / Weekly / M onthly
Spec ific E nergy cons umption
Weekly Review at Refinery C hief level
norms vs . ac tual
O verall CEL (C orrec ted energy M onthly (V alues dis played on internal
and L oss I ndex - SHEL L ) Web s ite)
M onthly (V alues dis played on internal
Plant wise CE L (E nergy I ndex)
Web s ite)
EII (Solomon E nergy I ntensity
M onthly
I ndex)
Flare L oss D aily / Weekly
U naccounted L oss Weekly / Monthly
Furnac e E ffic iency Weekly
O ther c ritic al Parameters ( Suc h
M onthly
as Captive power plant effic iency)

Implementation of corrective actions from

ISO 14000 Certifications (Example)
Well -st ru ctu red EMS, cert ifi ed t o ISO 1 4001 :2004 st a n da rd.

14
Implementation of corrective actions from
ISO 14000 Certifications (Example)

Furnace Monitoring Web Page

15
 Furnace Monitoring Web Page

Furnace Monitoring Web Page

16
Furnace Monitoring Web Page

Weekly Fired Heaters Performance

Monitoring Report

17
 Daily Flare Monitoring Report

Weekly Energy Monitoring Report

18
 Renewable Energy Sources, Environmental
Projects & Utilization of Waste
Initiativ es h a s been ta ken :
1 . Ren ewa bl e En ergy Sou rces
Sola r Wa t er Heat ers in t own shi p :
• Dom esti c gey sers were u sed in
town shi p whi ch con sum es m ore
el ectri ci ty . Total 1300 S ol ar Heaters
are i nstall ed in n ew town shi p area
ou t of wh ich 1000 n o. ( 300 l i t cap.)
an d oth er 300 n o. ( 500 l i t cap.)
Project Ben efit s:
• Th is has resulted in savin g of 7,000,000 el ectri ci ty uni ts,
whi ch in tu rn hav e redu ced CO2 em i ssi ons by 6750 ton n es annu ally .
• Hi gh -effi ci en cy , Up to 75% en ergy sav ing, Eco-fri en dly , n o
exhau st gas, n o waste water drai n to h arm env ironm ents.

Renewable Energy Sources, Environmental

Projects & Utilization of Waste
2.Environmental Project
Tu be ligh t Di sposal Sy st em
Project Ben efit s

• Earli er fu sed tu bes were sol d as scrap

- exposu re of recy cl ers to th e vapour i s
eli minated.
• Th is facil ity en sures that Mercu ry
(Hg) em i ssi on is 0.02 m g/m 3
(av erage) whi ch i s far bel ow OS HA
Th resh ol d lim it valu e (TLV ) of 0.05
m g/m 3.
• Th is i n - si tu process provi des an edge
as it en sures proper disposal of
spen t/used tu be ligh ts in lin e wi th ou r
corporate social responsi bili ty (CSR).

19
 Renewable Energy Sources, Environmental
Projects & Utilization of Waste
3.Utilization of Waste Project

Project Benefits:-
Anaerobic Digestor
• Produce cooking gas from
Food waste and supplied to
canteens in labour colony.
• Biogas generation is around
23-25 m3/day having a
calorific value of 6100 – 7000
kcal/m3
• Reduction in volume of waste. Anaero bic Di gestor

Greening of Refinery - Sink for

Carbon Emission
• 1 ,02,000 Man go trees - Kesar & Li l ly -- 500 T/YEAR produ cti on .
• 1 ,50,000 Teak, Gm el in a, N eem & Ba kain N eem
• Ber, Gu ava, Cu stard A ppl e & A ml a
• 1 ,50,000 Th espasia , Parkinsoni a , Casuri na, Fi cus
• An d m any m ore speci es
• Total 1 8,00,000 trees in th e com pl ex.
• 2,200 a cres of th e total area cov ered by tree plan tati on

20
 En-Con Awards
• CII award for excell en ce i n En ergy Man agem ent – 2003, 0 4,05 & 06

• ICMA award for excell ence in en ergy managem en t – 2003 & 05

• Federati on of Gu jarat In dustri es Award for
excell en ce i n en ergy con servati on – 2004

• Nati onal En ergy Con servati on award – 2004 , 05 & 06

(Mi ni stry of Power)

• En ergy Con servati on A ward – PCRA (MoP&N G) – 2004 & 05

• CHT – Mi ni stry Of Petrol eum Award for excell en ce

in Area Of Steam Leak – 2005 & 07

• CHT – Mi ni stry Of Petrol eum Award for excell en t

Boi l er/Furnace performan ce – 2006

• In fralin e En ergy A ward for excell en t con tri bu ti on

to In di an En ergy Sector – 2007

Our mission
Clean Environment for sustainable development

Thank You

21