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Thank You

The Jamnagar Gasification Project


by
Dr. Partha Maitra
Reliance Industries, India


13 - 16
th
October, 2013 Colorado Springs, USA
Gasification Technologies Conference 2013


2
Index
Reliance
Jamnagar refinery
Integration
Gasification
Conclusion



3
Reliance: An introduction
Performance; FY13 $bn
Revenue/turnover 68.4
Exports 44.1
Earnings, EBDIT 7.1
Cash profit 5.6
Net profit 3.9
Net worth 32.7
Assets 58.0
Global Indian company
Segment performance % Oil & gas Refining Petrochem Others
Revenues 2.3 75.7 19.1 2.9
Earnings 15.3 53.5 29.9 1.3

Operates the worlds largest refinery @ Jamnagar
Owns 25% of worlds complex refining capacity
Among top 10 independent refiners
Flexible in crude sourcing + product exports
Generate higher margin per barrel, w.r.t peers
Low cost producer of refinery products
#1 in polyester, in the world
#107 in Fortune Global 500 (2013)

4
Jamnagar refinery
Worlds largest refinery + petrochemical complex
Crude processing : 1360 kb/d (FY13), 1.8% of global refining
Coker : 340 kb/d VR feed
: 2 x 8 drum cokers, largest in the world
: 6 mmt/yr petcoke production
LNG import : 3.4 bcm/yr (FY13)
Utilities & power : Cogen captive power plant, w/ GTG + HRSG
: 1505 MW existing power + stm equiv.
New projects : C
2
complex: 1650 kt/yr C
2
=, + 150 kt/yr C
3
=
: Recover ethane + ethylene in RFG
Crack ethane to ethylene + C
2
derivatives
: Cracker + MEG + LDPE + LLDPE/HDPE
: PX-4: 2330 kt/yr PX + 560 kt/yr benzene
: Upgrade reformate to aromatics
PX recovery + Isom + Transalky + Ex. Dist.
5
Gasification: Profile
Configuration : Worlds largest w/ 10 gasifiers
Feed : Petcoke, w/ coal blend flexibility
Output : 8.0 bcm/yr syngas, NG equiv; 2.6 million Nm
3
/hr syngas
Product : Cogen fuel : Produce power + steam
H
2
: Eliminate on-purpose H
2
SNG : Refuel existing heaters
Htr fuel : Fuel new heaters
CO : Feed to acetic acid
Driver : Substitute LNG w/ petcoke import

: Minimize refinery opex

: Boost refinery margin
Worlds largest gasification complex
6
Refinery gasification integration
Integrate refinery + gasification
Refinery Gasification
Existing
New
Petcoke
Petcoke import
Crude
H
2
SNG
Syngas/cogen fuel
LNG import
Syngas/htr fuel
7
Petchem gasification integration
Integrate petchem + gasification @ Jamnagar
Refinery
Gasification
PX-4
C
2
complex
MEG
LDPE
LLDPE/HDPE
Syngas/cogen fuel
C
2
+ C
2
=
H
2
Crude
Petcoke
H
2
SNG
Syngas/htr fuel
Syngas/cogen fuel
PX
Benzene
Reformate
Existing
New
Syngas/cogen fuel
Acetic
acid
Acetic
acid
CO
Return
8
Demand profile
Satisfy Jamnagar utility demand w/ syngas from gasification
Cogen CPP Power + steam MW Integration
Existing 1505 48% power + 52% steam equiv.
New projects 350 All power
Gasification 650 Parasitic, incl. stm equiv
Total 2505 Cogen fuel demand
Heater fuel RFG G cal/hr
Existing 2010 SNG as fuel
New projects 360 Syngas fuel for new htrs
Total 2370 SNG + syngas demand
H
2
H
2
t/d
Capacity 1440 8 stm. methane reformer
Existing demand 1175 On-purpose
New project (400) H
2
from C
2
complex
Total 775 H
2
from syngas
9
Driver

Petcoke : Lowest value refinery product
: Bottomless refinery w/petcoke gasification
Syngas : 100% captive consumption @ Jamnagar
: Consumption = Cogen fuel, SNG/syngas as htr fuel, H
2
and CO
: Beat LNG import price
: Cost : Feed + opex + capex = Lifecycle
$/mmbtu : 3.5 + 2.4 + 5.3 = 11.2
Refinery : Minimize refinery opex to boost refinery margin
Petchem: Recover CO for new acetic acid plant
: Swap SNG w/ C
2
+ C
2
= in RFG, as advantage petchem feed
Boost refinery margin + add value w/ petrochem
10
Project profile

Configuration : 10 gasifiers, in 5 modules w/ 2 gasifiers each
: Large gasifiers @ 1170 MWth input/gasifier
: Gasify petcoke to syngas
Feed : 9.8 mmt/yr petcoke
: 6.0 mmt/yr captive + 3.8 mmt/yr import
: Feed flexibility, w/ 35% coal in blend
: Upgrade petcoke
Product : Syngas = 8.0 bcm/yr, NG equiv.
: 100% captive consumption @ Jamnagar
Max refinery + petrochem + gasification synergy
11
Product profile
Syngas bcm/yr % Routing
Cogen fuel 5.05 63 Existing + new GTG + HRSG
H
2
1.3 16 Existing H
2
header/Hydrotreater feed
SNG 1.1 14 Existing RFG header/Htr fuel
Heater fuel 0.4 5 New htr. fuel
CO 0.15 2 New acetic acid feed
Total 8.0 100
Boost refinery + petrochem performance
Gasification : Fuel + H
2
for refinery
: Feed + fuel for petchem
12
Product summary
Cogen fuel : Repower existing + new GTG + HRSG for captive power + steam
: Power + steam = 2505 MW; existing =1505 MW, new = 1000MW
H
2
: Supply H
2
for clean fuels, equiv. to 775 t/d H
2
: Shut down existing H
2
plants
SNG : Recover C
2
+C
2
= to feed new Cracker in C
2
complex

: Substitute C
2
+C
2
= w/ SNG @ 2010 G cal/hr
Heater fuel : Fuel all new process heaters w/ syngas @ 360 G cal/hr
CO : Feed 450 kt/yr CO to new acetic acid plant
By products : Sulphur
Future proof : NH
3
recovery
: CO
2
capture
: Metals recovery
Optimized gasification product slate
13
Energy flow diagram - schematic
Gasification product slate
Gasifier
100
25.8
Loss
8.8
Parasitic
4.9
53.6
2.7
5.0
25.0
6.5
54.6
Syngas/new
htr fuel
Syngas/
cogen fuel
1.0
1.7
10.6
SNG/existing
htr fuel
12.4
12.4
H
2
Loss
6.1
125.8
Loss
0.9
Petcoke
CO
CO reco
SNG
Shift
PSA
14
Configuration
Optimized scope
Gasification : 10 gasifiers, 5 modules w/ 2 gasifiers each
ASU : 5 x 5250 t/d oxygen @ 99%
OGBL : Package, # # Open art, # #
AGR (unshift) 2 LTG cooling 2
AGR (shift) 2 Shift 2
PSA 1 SWS 8
CO recovery 1
SNG 1
SRU/TGT 4
SFU 2
OSBL : Offsites + utilities
Offplot : Solids movement & storage
15
Partners
Contractor: Licensor:
PMC Fluor Gasification CB&I Lummus (Phillips 66)
EPCM Fluor Open art Fluor
O&U Bechtel
Construction L&T Equipment suppliers:
Reactor + vessels L&T
Package suppliers: HTHR boilers Alstom
ASU Linde Rod mills Cemtec
AGR Linde Slurry pumps Geho/Flow serve
PSA Linde Char filters Porvair
SRU/TGT Worley Parsons Syngas rec. comp. Siemens
SFU Enersul Superheater Linde/Selas
GTG/GTG Mods GE
Cooling tower SPIG
Stacker/reclaimer Thyssen Krupp
Partners-in-place for Jamnagar gasification project
16
Mega project
# Gasification Associated Total
PFD 5 x 9 70 115
P&ID 5 x 210 640 1690
Piping isometrics 5 x 5100 7800 43,300
Equipment 1060 480 1540
ODC equipment 110 15 125
Major EPC effort
Source: Fluor
Detailed engineering
Task force : 400, to peak at 600
Man hour : 1.6 million
Location : Fluor, Houston & Delhi
17
Capex
Gasification %
License, engineering, consultancy 5
Equipment + packages 48
Bulk material 16
Construction 14
Others
(1)
7
Financing 5
Contingency 5
Total 100
Competitive capex
Note 1: Others freight, startup + commission, duties + taxes, preoperative, insurance, inspection
Jamnagar gasification = Projected at 75-83% of USGC capex
18
Status
Project kickoff May12
PFD review Complete
P&ID review + HAZOP Complete
30% model review Complete
Equipment/package awards 90% complete (end Sep13)
Detailed engineering 35% complete (end Sep13)
Construction Commenced in Apr13
Target startup = mid 2015
19
Conclusions
Make vs buy:
Petcoke gasification (make) beats LNG import (buy) in India/Asia
Bottomless refinery:
Zero petcoke, lowest price refinery product
Superior refinery margins
Utilities:
Repower cogen power plant w/ syngas
Recover H
2
from syngas, for refinery clean fuels
Utilize SNG + syngas as fuel for process heaters
Petchem feed:
Recover C
2
+ C
2
= for petchem feed w/ SNG substitution
Recover CO from syngas, for acetic acid
Supply utilities to new petchem projects
Success factor
Min capex
Meet or beat schedule
Max availability
Leverage gasification to boost Jamnagar refinery + petrochem performance
Thank You
Thank You