PROCESS OVERVIEW

(Mech., Elec., Inst. And Civil)

Reliance Petroleum
Limited
Jamnagar
Feb98
1

Contents
1.

Refinery overall block diagram

2.

Unitwise details
Block diagram
Purpose
Capacity
Technology
Salient features

JAMNAGAR
PROCESSES
3

Refinery Overall Block

Diagram
Naphtha
Kerosen
e
Petrol
Diesel
LPG
SBM
Crude

MTF

CDU/
VDU

FCC
Propylen
e
Coker
Sulfur

Aro
PP
MPP

PX
PP
Power
4

Captive Power Plant (Power &

Steam)
Air

Fuel

Steam

CC

HRSG
3 ph. power

Compressor

GT
Aux.
Boiler

HHP
LP
Condensate

HP

MP
3 ph. power
STG

Nitrogen generation
Vent
gases

N2

Molecular
sieves

ADU
Expander

Air
compressor

Super
cooler

Liq.N2
Liq.
O2

O2

Sea water intake

system

Stop
gate

Cl2

Chlorination
chamber
Fire water
Filtered sea waterpond
reservoir
To RTF
FW

network
Intake
Stilling
channel Stop
gate basin

Filter Fire water

reservoir

Design capacity for intake

channel & stilling
basin=22,000 m3/hr

Desal
water

Desal unit
Outfall
point 7

Multi Effect Distillation

Ejector
system
Condens
Vapor

Vapor

Vapor

Fresh
sea

wate
Steam

Brine
discharg

Steam
condensate
Distillate

1
1

Distillate Distillate

Power & utilities

GTG

6 x 30 MW
Total installed cap. :
300 MW

STG

4 x 30 MW

HRSG
AUX. BOILERS

6 x 125 T/hr
Total installed cap:
1,250 T/hr
4 x 125 T/hr

Utilities

(All units in m3/hr)

Design

Normal

Sea water

7,000

4,468

Desalination

2,000

1,569

Demineralisation

1,340

694

CT-1

23,310

12,849

CT-2

23,310

CT-3

23,310

CT-4

23,310

Air ( Nm3/hr )
Nitrogen ( Nm3/hr )

17,440
19,739
17,838

100,000

79,913

20,100

13,969

10

CDU/VDU
C3/C4
( To LPG Merox)
Naphtha to
hydrotreater
Light Kerosene
Heavy kerosene
Diesel

Sat. Gas
Conc Unit
Crude

Desalters
CDU

HAGO

Fired heater

VDU

Vacuum Gas Oil

to FCC Unit

Vacuum residue
to delayed coker

11

CDU/VDU
To distill crude oil into various fractions like LPG, naphtha,
kerosene , diesel , vacuum gas oil etc.
Capacity : 2 x 225 KBPSD
UOP,USA (licensor)
Salient features :
Largest grassroot single train CDU
Two stage Desalters in order to reach salt content of 1 PTB
in crude
Two Kerosene draws - Light and heavy to meet LAB plant
feed requirements and dual purpose kerosene
requirements i.e. ATF & SKO
Crude, vacuum and sat. gas conc. units are fully heat

12

Hydrotreater
M/u H2

Ovhd.
condensor

Recycle
gas

Offgas
to SGCU

Diesel

Diesel

VGO
LN

VGO

Product
separato
r
Hydrotreater

LN
Stripper

To waste
water
system

13

Hydrotreater
Purpose of hydrotreating unit is to :
Remove Sulfur & Nitrogen
Convert Olefins/Aromatics to sat. compounds
Remove contaminants like oxygenates & organomettalic
compounds.
Capacity: Diesel Hydrotreater
2x70,000 BPSD
VGO Hydrotreater 2x73,600 BPSD
LN Hydrotreater 1x29,500 BPSD
UOP,USA (licensor)
Salient features:
98% desulfurisation & 70% denitrification (Diesel
hydrotreater)
94% desulfurisation & 54% denitrification (VGO
14
hydrotreater)

FCC
Process air
BFW

Flue gas
Power
Recovery
Train

M/u catalyst

Reactor vapors

Treated gas

Steam
Spent
catalyst

Regenerator
Process air

O/H gases

LPG
Reactor

Regen.
catalyst

Main
Unsat
column Heavy gas conc.
naphtha

Gasoline
LCO

Steam Raw oil

Fuel oil

Naphtha

15

FCC
To crack heavy ends from VDU to produce lighter, more
valuable products at high temp. and moderate pressure
Capacity: 130 KBPSD
UOP,USA (licensor)
Feed: Vacuum gas oil
Salient features:
Largest FCC in the world.
Offers greater flexibility of operation (can be run in max.
LPG or gasoline or distillate mode)
Heat integration (power recovery train, heat pump in C3R
column)
Capable of handling very heavy feedstock.
Cheapest available coversion process.

16

Merox
Feed
LPG
Rich
amine

Feed

Reactor
ATU
Lean
amine

Air
mixer

Reactor

Catalyst
Caustic
Air

Extractor Caustic Sweet

KOD
LPG

Caustic
makeup

Caustic
settler

To ETS

Sweetened
Product

To ETS
17

Merox
Purpose is to remove inherent organic sulfur from LPG,
Kerosene and Gasoline.
Capacity: Unsat LPG Merox
Sat LPG Merox
Kero Merox
Gasoline Merox

60,000 BPSD
19,000 BPSD
70,000 BPSD
50,000 BPSD

18

SHP/TAME
Off
gas

Raffinate

C5
feed
Pentene
column
H2
SHP
React
or

Stripp
er

TAME
Reactor

TAME

19

SHP / TAME
Purpose of SHP is to convert di-olefins to mono-olefins in
order to facilitate production of Tertiary-Amyl-MethylEther in TAME unit which is used a good blending agent
for gasoline
Capacity :SHP :

660 KTPA

TAME :

210 KTPA

UOP,USA (licensor)
Salient features:
TAME is an octane no. booster

20

Hydrogen
H.P BFW
Recycle H2

Refinery Feed
fuel gas gas
compr.
Natural gas
LPG

Naphtha
(future)

Main
pumping
section

Steam
generator HP Steam export

Shift &
Product H
gas
Steam
Feed
Gas
cooling
purification reformer
purification

Refinery general
fuel gas

Waste gas

21

Hydrogen
To meet the hydrogen demand of the whole refinery by
steam reforming
Capacity: 2 X 181 TPD
Linde AG (licensor)
Feed: Refinery fuel gas /LPG/Natural gas/Naphtha(future)
Salient process:
Special PSA process supplies high hydrogen purity of
99.9%.
Special design of reformer involving use of low press. and
low calorific value gas as the major fuel
Provision for third train addition in future

22

Sulfur
Acid gases
from ARU
Thermal
reactor

Claus
reactor

CBA
reactor

Air
Condenser
1
Sour gases
from
WWSU

Condenser
2

Liquid sulfur
degassing pit

Condenser To tail ga
3
incinerat

To sulfur
granulation unit
Air

23

Sulfur
Sulfur recovery is required because of :
Increasing demand for environment friendly fuel
Use of high-S & heavier crudes in future
Tightening of emission standards by govt. / regulatory
bodies.
Capacity: 1350 TPD
Black & Veatch Pritchard Corp. ,USA(licensor)
Salient features :
3 SRU units
Minimum sulfur recovery level of 98.7%
Ammonia destruction capability
Turndown capability - 25%
Liquid Sulfur degassing system

24

Coker

Vacuum
residue
tank

FO
tank

Heavy cycle gas oil

LLP Flare
Light cycle gas oil
HP flare
To HNUU
To LNUU
Unsat gas
To LPG
conc. unit Unsat LPG
Coker
spheres
Merox unit
FG
To flare
distribution
Coker consumption
system
To light slop
oil tank
Rich
S/u
amine Lean amine
To heavy slop
Diesel
oil tank
Amine
Coke
treating
handling
To ETP 25
system

Coker
Value upgradation of crude residue into high value distillate
(naphtha, LPG , FG, diesel etc.) petroleum coke via
thermal cracking.
Capacity: 122 KBPSD
Foster Wheeler, USA (licensor)
Feed: Vacuum residue
Salient features:
Largest coker in the world
First coker with 8 coke drum operation
Largest coke drum ever built (29 ft. dia.)
Petroleum coke will be used for mega power plant
Capability to process refinery slop & sludge

26

Aromatics
Off gas to
FG

LPG
Debut/PSA
LN
H2 Regen cat.
gas to FG
H2
Spent cat.
Plat./Rec.
Plus/
Feed
HNNU
PSA
Cycle
Off
gas
Bz.
max.
C7A
from
Tat/Iso
Off gas
CCR
Reformate
Light
Toluene Parex
Px
reformate
Tat.
Raffinate Off gas
3 Trains
C8A+
Parex
Dehp. Off
M/u H2
m/u H2
feed
gas to FG
Ox
+
C
from Tat.
from Plat.
9A+
C A
Xyfrac
Iso.
Ox
Mix
OX frac
3 Trains
3 Train
xylenes
C10A to
Heavy aro.
from 27
gasoline
To FO
Hazira
9

Aromatics
Designed to produce paraxylene and orthoxylene from
Naphtha feedstock
and mixed xylenes.
Capacity: Paraxylene
Orthoxylene

1,200,000 TPA
150,000 TPA

UOP, USA (licensor)

Salient features:
3 parallel trains each of 400,000 TPA.
Worlds largest PX plant in a single location
Compared to PG plant, special Recovery plus unit & PSA
unit included to produce LPG and high purity Hydrogen

28

Polypropylene

Reacto
r
propylen
eethylene
additiv
e

Extruder

Storage &
handling

29

Polypropylen
e
Designed to produce homo, random & impact copolymers
Capacity:

400,000 TPA

UCC, USA (licensor)

Salient features:
Repeat plant from Hazira
2 parallel trains each of 200,000 TPA
Provision for the third train in future
Capable to produce about 90 different grades
Magnetic bearing for extruders
30