ril jamnagar
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1
Reliance Jamnagar Complex
CII
National Awardfor
“Excellence in Energy Management – 2008”
By
H. V. LOD HIA – Team Lea der
R. R. K AMDI
S. KHANDELWAL
August 22-23, 2 008
Content
• Overview of Jamnagar Refinery
• Energy Conservation efforts
• Comparison with Global Benchmark
• ENCON Projects
• Monitoring & Reporting formats
• Environment Concerns
2
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, VDUs, 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
3
Reliance Jamnagar Process Overview
Integrated refinery, adding valu e to share holders.
LPGLPG
Fuel GasHydrogen
PC Naphtha
Benz en eGasoline
OXHeavy Naphtha
PX Naphtha
SKO / AT FATF / S KO
Kero sen e PP HSD
CRUDE
Dies el LPG Fuel Oi l /
HSD GT Fuel
Benz en eVGO Gasoline OX
PX
TAMECoke
Vacuum R es idue NaphthaNaphtha
Coke Sulfur
Acid Gas PPSulfur
SWS Gas
CDU / VD U
VGOHT
Dies el HT
Kero M erox
Naphtha Splitter HNHT
FCC GasolineMerox
DelayedCoking Unit
LNHT
SHP / TAM E
pRODUCT
BLENDING
BLOCK
LPG Merox
Unsat LPG Merox
PRU
Hydrogen Manufacturing Unit
ATU
SRU
SWS
Marine / Oi l Movement &
Storage
Power & Utilities
Plat former Aromatics
PP
• 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 Jamnagar as Refining hu b of the world
Jamnagar SEZ Export Refinery Overview
4
Jamnagar : Refining Hub of the World
So urce: Oil and Gas Jo urnal
BPSD
RIL – RPL combine to be the largest refinery complex in the world
RIL Group, India 1,230,000
458,000
493,500
495,000
520,000
557,000
580,00 0
605,000
650,00 0
817,000
940,000
650,000
0 200,000 400,000 600,000 800,000 1,000,000
Shell Eastern, Singapore
Exxon Mobil, Baton Rouge, USA
Hovensa LLC, Virgin Islands
S-Oil Corp, So uth Korea
Exxon Mobil, Baytown, USA
RPL's Propo sed R efi nery
Exxon Mobil, Singapore
LG -Caltex, South Korea
Relian ce Ind ustries Ltd, Ind ia
SK Corp, So uth Korea
Paraguana Refining, Venezuela
Most complex refinery in the region
5 10 15 20 25 30 35
2 4 6 8
Reliance
BPCLKoyali
HPC L & CRL
BRP LVizag
Bara uni
Digboi
Haldia
Mathura
MRL & Pani pat
MRP L
Capacity ( MMTP A)
Co
mp
lex
it
y (
In
de
x)
Large & hi gh margi n Economy of Scal e
Small & l ow margi n
RIL Refinery – Way Ahead of Competition
5
En-Con Efforts in last 3 yrs
57844335810Total
617818604200 5-063
63579186032006-0 72
3248463832007 -081
Month sRs.
Lakhs/ AnnumRs. La khs
Payback Perio dSavingsInvestment
No. of Projects Implemented
YearSr. No
En-Con Efforts in last 3 years
En-Con Projects in the Year 2007 - 08
32484637.5 3Total
1944.53Hydrotre aters st ripper HP steam replacem ent by MP stea m
3
41290441
Increase in c rude preheat tempe rature by 20°C in Crude D istiller-1 by Heat recov ery from h ot VG OHT product stre am (P inch Technology)
2
2110 0192Heat recove ry from New P late-F rame type Rich /lean Amine Heat Exchange r in 2 train s of ATU by replacing Shell & Tu be HE
1
Month sRs.
Lakhs/ AnnumRs. Lakhs
Payback Period
SavingsInvestment
Project ImplementedSr. No
En-Con Projects implemented in the Year 2007-08
6
Specific Energy Consumption
34.02007-088
36.32006-077
39.62005-066
42.62004-055
45.82003-044
46.72002-033
47.22001-022
48.72000- 011
Energy Consumpti on (Kbtu/bbl /NRGF )YearSr. No
Specific Energy Consumption
CEL 95.6 in 2000CEL 93.9 in 2001CEL 88.7 in 2002CEL 87.6 in 2003CEL 86.9 in 2004CEL 89.5 in 2005CEL 86.9 in 2006
Shell Benchmarking Performance
80
100
120
140
160
180
200
220
JAM2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Inde
x.
CEL Index SBR
Corrected Energy and Loss Index - 85.4 (2007)
80
100
120
140
160
180
200
220
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Inde
x.
CEL Index SBR
Performa nce of other Interna tional Re fineries (Hi gh CEL)
Reliance, Jamnagar Refin er y continuous to be the Pacesetter
CEL 95.2 in 200 0CEL 94.4 in 200 1CEL 88.7 in 20 02CEL 87.6 in 200 3CEL 86.9 in 2004CEL 89.5 in 20 05CEL 86.9 in 2006CEL 85.4 in 20 07
Energy Performance Indi cator - CEL
7
Solomon Benchmarking Performance
Energy Intensity Index (EII - Solomon) - Trend
697072
50
58
66
74
200620042002
Year
EII
Performance Summary : Solomon Benchmarking 2006Asia/Pacific Excluding Japan
95.995.9 60.860.8
60.460.4 471.1471.1
7.37.3 48.548.5
66.766.7 131.1131.1
31.531.5 79.879.8
10.910.9 --0.980.98
98.198.1 91.791.7
25.525.5 --0.290.29
Cash Operating Expense, U S cents/UEDCCash Operating Expense, U S cents/UEDC
Energy Intensity IndexEnergy Intensity Index
Maintenance Index , U S $/EDCMaintenance Index , U S $/EDC
Personnel Index , W ork Hours/100 EDCPersonnel Index , W ork Hours/100 EDC
Refinery Utilizati onRefinery Utilizati on
Mechanical AvailabilityMechanical Availability
Net Cash Margin, U S $/bblNet Cash Margin, U S $/bbl
Return on Investment, %Return on Investment, %RR
RR
RR
RR
RR
RR
RR
RR
35.6
69
6.6
127.4
91.5
95.7
11.3
28.8
RIL
8
IMPROVEMENT STRATEGIES
Current Performance
Pot ential Performance
GAP
Time
4. Benchmarkingmaintains stimulus for
continuous improvement
1. Benchmarking identifiesopportunities for improvement
2. Application of"Best Practices"
3. Benchmarking helpsto measure success in
closing the gap
Pe
rfo
rma
nce
RIL JAMNAGAR Road Map to achieve Best
Reliance Jamnagar Complex
Innovative En-Con Projects
9
En-Con Projects at RIL, Jamnagar
1. Reduction in steam consumption in stripper reboilers Of Amine Treating units (ATU).
– ATUs funct ion is to rem ov e H2S & CO2 fr om FG or LPG & to
reg enerate th e rich am ine to lean am ine in stripper
– In or iginal design Lean amine fr om stripper bottom r outed
thr ough a Sh ell & Tube HE to heat rich am ine feed to stripper
– Appr oach temp. in Shell & Tube HE wa s 48 oC
– Replacement of S & T HE with Plate & Fram e HE carried out
to in crea se th e h eat r ecov ery fr om h ot lean am ine into the rich
amine feed to stripper.
– Appr oach temp. in New Plate & Frame HE is 27 oC.
– Steam con sumption in str ipper reboiler reduced due to incr ea se
in heat recov ery , redu ction in GHG emission
En-Con Projects at RIL, Jamnagar
Stripper reboiler i n Ami ne Treating U nit
Acid Gas to Knock-Out Drum
Rich Amine from Rich Flash Drum
Rich / Lean Amine Heat Exchanger(Shell & Tube type)
Rich Amine to Amine Stripper
Lean Amine from Amine Stripper
Lean Amine to Lean Amine cooler
Rich / Lean Amine Heat Exchanger (Plate & Frame type)
AmineStripper
1310C
83 0C
131 0C
104 0C
59 0C
59 0C
86 0C
107 0C
Lean Amine Pump
LP Ste am from CPP
Amine stripper Reboilers (2 Nos)
with new Pl ate & Frame Heat Ex changer
Phot ograph
Amine Stripper
10
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)
11
En-Con Projects at RIL, Jamnagar
2. Increase in Crude Preheat Temperature from 247 oC to 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 to 145 oC by h ot Naphtha PA*, HK PA, Diesel PA, LK & VR product
streams
– In warm preheat train, Crude is preheated from 145 oC to 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 to 247 oC by hot HVGO PA, HAGO PA, Slope wax PA & VR streams.
– 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 optimization was carried out using the Pinch Techn ology to exploit potential av ailable of integrating CDU with other units
– Modification s have been implemented in the hot preheat
exchanger train of CDU-1 which inv olv ed Hot VGO stream r outing fr om VGOHT-1 to CDU-1
– Additional exchangers were added a s 3 rd parallel Hot preheat train
to extract heat av ailable in Hot VGO stream for preheating crude
– This has increased the inlet temperature of Crude Heaters by 20 oC (from 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 combined which is equiv alent to sav ing of 20,000T /yrof fuel oil
– The cost of implementation of this pr oject was Rs.44.10 Million
12
En-Con Projects at RIL, Jamnagar
En-Con Projects at RIL, Jamnagar
13
Carbon Emission Reduction Projects at RIL, Jamnagar
Estimate d CE R70,000Fuel Gas firing in Gas Turbines 6
Validation over 23174Redu ctio n in steam d emand fo r Naphtha splitter rebo iler in Coker thro ugh inno vati ve pr ocess in tegration.
3
Validation over96867Redu ctio n in steam con sum ptio n in str ipp er reboil er of ATU by rep lacin g Shell & Tube HE w ith P late & Frame HE.
2
4,45,7 31Total
Estimate d CE R94,000Inlet air fo gging in Gas T urbines in CPP 9
Estimate d CE R18,000Re-routing of LPG Merox gases to co mbustion air in CDU -2 (t o enable dis posal of VDU off gases in f urnaces)
8
Estimate d CE R17,000Routing of rich amine flash gases in V GO HT to ATU sat gas absorbe rs
7
PDD Pr epar ed45,000Coker Blow-do wn Ven t Gas reco very 5
PDD Pr epar ed45,000Main Flare Gas Recover y4
Register ed wi th UNFCCC & veri fi ed
two ti mes36690Rerou tin g of Sat Gas Con Stripp er off gas es dir ec tl y to
Primar y absorb er feed by passin g HP receiver in CDU I/II 1
Remar ksAnnual CER (MT of CO2)
Project Activity D escriptionSr. No.
En-Con Team
14
Monitoring and Reporting Practices
Monthly Other c ritical Parameters ( Such as Captive power plant effic iency)
WeeklyFurnace E ffic iency
Weekly / MonthlyUnaccounted Loss
Daily / WeeklyFlare Loss
MonthlyEII (Solomon Energy Intensity Index)
Monthly (V alues displayed on internal Web s ite)
Plant wise CEL (Energy Index)
Monthly (V alues displayed on internal Web s ite)
Overall CEL (C orrec ted energy and Loss Index - SHELL)
Weekly Review at Refinery C hief levelSpec ific Energy consumption norms vs . ac tual
Daily / Weekly / MonthlyFuel & Loss
Monitoring/Reporting FrequencyParameter
Implementation of corrective actions from ISO 14000 Certifications (Example)
Well -structured EMS, certifi ed to ISO 14001:2004 standard.
15
Implementation of corrective actions from ISO 14000 Certifications (Example)
Furnace Monitoring Web Page
16
Furnace Monitoring Web Page
Furnace Monitoring Web Page
17
Furnace Monitoring Web Page
Weekly Fired Heaters Performance Monitoring Report
18
Daily Flare Monitoring Report
Weekly Energy Monitoring Report
19
Renewable Energy Sources, Environmental Projects & Utilization of Waste
Initiativ es has been taken :
1. Renewabl e Energy Sources
Solar Water Heaters in townshi p :
• Domestic geysers were u sed in
township which consumes more
electrici ty . Total 1300 S olar Heaters
are installed in new township area
ou t of which 1000 no. ( 300 l i t cap.)
and other 300 no. ( 500 l i t cap.)
Project Benefits:• This has resulted in saving of 7,000,000 electrici ty units,
which in tu rn have redu ced CO2 emissions by 6750 tonnes annu ally .
• High-efficiency, Up to 75% energy saving, Eco-friendly, no
exhau st gas, no waste water drain to harm environments.
Tube light Di sposal Sy stemProject Benefits
• Earlier fu sed tu bes were sold as scrap
- exposu re of recyclers to the vapour is
eliminated.
• This facil ity ensures that Mercu ry
(Hg) emission is 0.02 m g/m 3
(average) which is far below OS HA
Threshold limit valu e (TLV ) of 0.05
mg/m 3.
• This in - si tu process provides an edge
as it ensures proper disposal of
spent/used tu be lights in line with ou r
corporate social responsibili ty (CSR).
Renewable Energy Sources, Environmental Projects & Utilization of Waste
2.Environmental Project
20
Anaerobic Digestor
Anaerobic Di gestor
Project Benefits:-
• 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.
Renewable Energy Sources, Environmental Projects & Utilization of Waste
3.Utilization of Waste Project
• 1,02,000 Mango trees - Kesar & Li l ly -- 500 T/YEAR produ ction.
• 1,50,000 Teak, Gmel ina, N eem & Bakain N eem
• Ber, Gu ava, Cu stard A pple & A mla
• 1,50,000 Thespasia, Parkinsonia, Casurina, Ficus
• And many more species
• Total 18,00,000 trees in the complex.
• 2,200 acres of the total area covered by tree plantation
Greening of Refinery - Sink for Carbon Emission
21
• CII award for excellence in Energy Management – 2003, 04,05 & 06
• ICMA award for excellence in energy management – 2003 & 05
• Federation of Gu jarat Industries Award forexcellence in energy conservation – 2004
• National Energy Conservation award – 2004 , 05 & 06(Ministry of Power)
• Energy Conservation A ward – PCRA (MoP&N G) – 2004 & 05
• CHT – Ministry Of Petroleum Award for excellencein Area Of Steam Leak – 2005 & 07
• CHT – Ministry Of Petroleum Award for excellent
Boi ler/Furnace performance – 2006
• Infraline Energy A ward for excellent contribu tion to Indian Energy Sector – 2007
En-Con Awards
Our mission
Clean Environment for sustainable development
Thank YouThank You
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