RIL Jamnagar

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

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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


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


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


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


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


– 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



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



17


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).


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.


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

Documents

RIL Jamnagar