Petcoke Gasification + Syngas Utilization at Jamnagar, India

Transcription

1 Petcoke Gasification + Syngas Utilization at Jamnagar, India Thank You Partha P Maitra + Antony Francis Reliance Industries Ltd 17 th Oct 2017 Colorado Springs, USA

2 Disclaimer Any statement, opinion, prediction, comment, or observation made in this presentation/publication are those of the presenter/author only and in no condition should be construed necessarily representing the policy and intent of Reliance Industries Ltd. (RIL). The information presented herein are of the presenter/author s own and in no way RIL attracts any liability for any inconsistency or irregularity in terms of the accuracy completeness, veracity, or truth of the content of the presentation/publication. In addition, RIL shall not be liable for any copyright infringement and misrepresentation for the presented content as the content is presumed in good faith to be a creation of presenter s/author s own mind. The scope of this presentation/publication is strictly for knowledge sharing purposes and not necessarily to provide any advice or recommendation to the audience/readers. Any endorsement, recommendation, suggestion, or advice made by the presenter/author shall be in his personal capacity and not in professional capacity as an employee of RIL. Any person acting on such endorsement, recommendation, suggestion, or advice will himself/herself be responsible for any injury/damage. Reliance Industries Ltd. 2

3 Index Reliance & Jamnagar refinery Petcoke gasification Base syngas utilization Gasification enhancements Future syngas utilization Conclusion 3

4 Reliance: An Introduction Reliance Industries Ltd, India #1 company in India, in private sector Global rankings, (Fortune 2017) #203 in revenues;#110 in profits Performance, FY 17 $bn Revenue 50.9 Earnings, EBDIT 8.6 Market capitalization 66.1 Net worth 44.5 Growth, CAGR (1) % Earnings 26.7 Market capitalization 31.5 Net worth(nw) 13.9 Returns (adjusted) (2) % ROCE 25.4 RONW 16.8 Note: (1)CAGR =compounded annual growth rate since IPO in 1977 (2) Adjusted for work in progress Indian company, with a global footprint 4

5 Jamnagar Refinery : A profile Jamnagar refinery Largest refinery Crude processed, kb/d 1380 World rank,# 1 Superlative performance Complexity Index 12.7 Energy Intensity Index 64 Availability,% ~97 Integrated complex Petrochemicals, %of crude 14.5 Utilities & power, % captive 100 Ports & terminal 5 SPM + 5 berth jetty Global exports By revenues,% 51 By volume, % 56 Margins GRM,FY 17 $/bbl Jamnagar 11.0 USGC/WTI 8.7 Singapore/Dubai 5.8 Rotterdam/Brent 5.3 Note: GRM = Gross refining margin Arguably the best refinery in the world 5

6 Jamnagar Gasification Mission: Project: Substitute LNG with syngas from petcoke gasification PMC = Fluor Switch from LNG to petcoke imports Licensor = CB &I s E-Gas technology Minimize refinery + petrochemicals opex, with petcoke Syngas utilization = 100% captive for H2 + plant fuels Maximize value addition with Refinery Offgas (ROG) Cracker Scale = 2 nd largest, after Pearl GTL, Qatar Boost refinery margins or GRM Complexity = World s largest construction site Scope : Crude oil 1380 kb/d Refinery 4 trains Fuels Diesel + jet + gasoline Petrochemicals LNG Import Vac resid 340 kb/d Coker 2 x 8 drums Fuels GWth 23.2 mmscm/d NG equiv. Petcoke = 9.1% of crude feed Petcoke import Pet coke 6.3 mmt/yr 4.0 mmt/yr Petcoke Gasification 10 gasifiers Sulphur Gasify petcoke to syngas, for 100% Jamnagar consumption 2000 t/d 6

7 Jamnagar Integration 730 C 2 + C 2 = 1900 H Import ROG Cracker + C 2 = derivatives Syngas MEG LDPE LLDPE C 3 = Olefins Crude Petcoke 10,300 Refinery H SNG Petcoke Gasification Syngas Syngas Return Reformate PX PX Benzene Aromatics Existing New Note: SNG = Substitute natural gas; MEG = Mono ethylene glycol; LLDPE Linear low density poly ethylene; PX = Paraxylene In kt/yr Gasification : Pivot for refinery + petrochemicals integration 7

8 Syngas Utilization Syngas mmscmd, NG eq % Processing Licensor / Supplier End use Cogen fuel AGR/SRU Linde/Worley Parsons Power & steam H Shift / PSA Fluor / Linde Ultra low S fuels SNG Methanation JM Davy Existing heater fuel Heater fuel LBG heaters Linde / Heurtey New heater fuel Total AGR = Acid gas removal; PSA = Pressure swing adsorption; LBG =Low Btu gas Syngas H 2 Cogen fuel Heater fuel SNG Base Utilization To refinery for clean fuels, ultra low S gasoline + diesel To GTG/HRSG for captive power + utilities To new heaters + superheaters, designed for LBG To existing heaters, for releasing C2 + C2= as feed to ROG Cracker Note: GTG = Gas turbo generator; HRSG = Heat recovery steam generator 100% syngas utilization for H2 + plant fuel 8

9 Petcoke Gasification Complex Integrated complex spread over 720 acres 9

10 Project : Scope Engineering: # PFD 115 P & ID 1700 Equipment: # Equipment 2920 Piping isometrics 44,000 Materials: Quantity Concrete, million cum 1.1 Structural steel, kt 210 Piping, million in m 14 Electrical cable, km 3900 Instrumentation cable, km 6500 Construction: # Construction workers, peak 65,000 Cranes, peak 900 Flagship gasification project of the world 10

11 Project Status Status, % complete Phase 1 Phase 2 Gasifier, # 4 6 Engineering Procurement Construction Pre commissioning Commissioning Ongoing -- Critical path AGR -- Start up Q4,2017 H1,2018 Gasification - Reactor Jamnagar petcoke gasification: At the cusp of start up 11

12 Gasification: Future Enhancements NH 3 Urea V Ethanol APC + RTO Recover 140 kt/yr from sour water 43% from gasification + 57% from refinery Convert N, a crude contaminant, into an opportunity Substitute imports, into India Exploit pure CO 2 from gasification shift Add CO2 to NH3, recovered + imports Boost fertilizer supply + food security of India Recover 9.5 kt/yr from gasification slag Recover 2.0 kt/yr as co product Convert V, a crude contaminant into a metals opportunity Global #1 in V, a micro alloy for high strength steel Exploit syngas for synthetic ethanol Use biochemical reaction kinetics Blend ethanol into crude derived gasoline Stretch gasoline without crude increase Develop integrated gasification model Model scope = 10 gasifiers + syngas headers APC = Advance process control RTO = Real time optimization using ROMeo software Enhance gasification performance Enhance gasification economics AGR Methanol Wash column 12

13 Future Syngas Utilization Gasification Syngas H 2 /CO = 0.62 Syngas 40% discount to LNG derived syngas Base syngas utilization = H2 + plant fuel Future syngas utilization = Oxygenated chemicals CO Recover CO from low H2/CO syngas Exploit low cost CO feed for acetic acid + ethylene glycol Derive acetyl chemicals from acetic acid Acetates + VAM + VAE + PVacetate + PValcohol Ethylene glycol, via unconv.process from CO Acrylic acid,via unconv. process from CO, in future Syngas Target chemicals, requiring low H2/CO syngas as feed Oxo alcohols + DME + MMA/ PMMA Blend DME into crude derived LPG Avoid NH3 + methanol, requiring high H2/CO syngas CO 2 Develop technology for CO 2 recovery Identify technology for CO2 utilization/sequestration Maximize value addition with syngas to chemicals 13

14 Conclusion Gasification Utilize petcoke, lowest value refinery product as gasification feed Eliminate petcoke sales + LNG imports to boost Jamnagar GRM Supply discounted H2 to maximize ultra low S gasoline + diesel from refinery Enable petrochemicals from the ROG Cracker, with C2 + C2= / SNG swap Transform Jamnagar into an iconic refinery, with petcoke gasification Gasification enhancements Value add gasification streams for NH 3 + urea + V + ethanol Target best-in-class gasification performance with APC + RTO Syngas utilization Exploit CO recovered from syngas for acetic acid + ethylene glycol + acrylic acid Acetic acid can be a building block for acetyl chemicals Exploit low H 2 /CO syngas for oxo alcohol + DME + MMA/PMMA DME can be blended into LPG, to stretch crude derived LPG Transform Jamnagar into an iconic chemicals complex, with CO + syngas Jamnagar petcoke gasification = Fountainhead for future syngas to-chemicals 14

15 Thank You