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

Reliance Petroleum Limited

Jamnagar

Feb’98

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Contents

1. Refinery overall block diagram

2. Unitwise details

• Block diagram

• Purpose

• Capacity

• Technology

• Salient features

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JAMNAGAR PROCESSES

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MTF

Coker

Naphtha

KerosenePetrol

Diesel

LPG

SBMPropylene PP

Sulfur MPP

Aro PX

PP

Power

Crude

Refinery Overall Block Diagram

CDU/

VDUFCC

Captive Power Plant (Power & Steam)

GTCompressor

HRSG

STG

Aux. Boiler

HHP HPMP

LP Condensate

SteamAirFuel

CC

3 ph. power

3 ph. power

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Nitrogen generation

Air compressor

Molecular sieves

Super cooler

N2

Liq.N2

Liq. O2

O2

Expander

Vent gases

ADU

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Sea water intake system

Stilling basin

Filter

Chlorination chamber

Desal unit

Fire water pond

Fire water reservoir

Intake channel

Stop gate

Outfall point

To RTF

FW

network

Stop gate

Design capacity for intake channel & stilling basin=22,000 m3/hr

Desal water

Cl2 Filtered sea water reservoir

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Multi Effect Distillation

Ejector system

Condenso

rVapor Vapor Vapor

Steam condensate

Brine discharge

Steam

Distillate Distillate Distillate

Fresh sea

water

1 2 11

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Power & utilities

GTG 6 x 30 MW Total installed cap. : 300 MW

STG 4 x 30 MW

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

AUX. BOILERS 4 x 125 T/hr

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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 17,440

CT-3 23,310 19,739

CT-4 23,310 17,838

Air ( Nm3/hr ) 100,000 79,913

Nitrogen ( Nm3/hr ) 20,100 13,969

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Desalters

CDU

Fired heater

Crude

Sat. Gas Conc Unit

C3/C4

( To LPG Merox)Naphtha to hydrotreater

Light KeroseneHeavy keroseneDieselHAGO

VDU

Vacuum residue to delayed coker

Vacuum Gas Oilto FCC Unit

CDU/VDU

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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 integrated.

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Hydrotreater

Reactor

To waste water system

Stripper

Offgas to SGCU

Diesel

VGO

LN

Diesel

VGO

LN

Ovhd. condensor

Product separator

Recycle gas

M/u H2

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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

hydrotreater)• Provision for 3rd train each for diesel(70,000 BPSD) &

VGO(73,600

BPSD)

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RegeneratorReactor

Maincolumn

Unsat gas conc.

PowerRecovery

TrainBFW

Process air

M/u catalyst

Process air

Flue gas

Steam

Regen. catalyst

Spent catalyst

Raw oilSteam

Reactor vaporsO/H gases

Treated gas

NaphthaFuel oil

LPG

Heavy naphtha

LCO

Gasoline

FCC

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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.

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Merox

ATU

Feed LPG

Leanamine

Richamine

Reactor Extractor Caustic KOD

SweetLPG

Causticmakeup

To ETS

FeedAirmixer

AirCatalystCaustic

Reactor Caustic settler

To ETS

SweetenedProduct

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Merox

Purpose is to remove inherent organic sulfur from LPG, Kerosene and Gasoline.

Capacity: Unsat LPG Merox 60,000 BPSD

Sat LPG Merox 19,000 BPSD

Kero Merox 70,000 BPSD

Gasoline Merox 50,000 BPSD

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SHP/TAME

H2

C5

feed

SHP Reactor

Off gas

Stripper

TAME Reactor

TAME

Raffinate

Pentene column

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SHP / TAME

Purpose of SHP is to convert di-olefins to mono-olefins in

order to facilitate production of Tertiary-Amyl-Methyl-

Ether 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

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Feed gas

compr.

Steam generator

Feed purification

Steam reformer

Gas purification

Shift &gas

cooling

Refinery fuel gas

H.P BFW HP Steam export

LPG

Naphtha (future)

Recycle H2

Natural gas

Waste gasRefinery general

fuel gas

Product H2

Hydrogen

Main pumping section

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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

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Sulfur

Thermal reactor

Condenser1

Claus reactor

CBA reactor

Condenser3

Condenser2

Liquid sulfurdegassing pit

Air

To sulfur granulation unit

To tail gasincinerator

Acid gasesfrom ARU

Sour gasesfrom WWSU

Air

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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

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Amine treating

Vacuum residue tank

FO tank

Coker

Coke handling system

Unsat gas conc. unit Unsat LPG

Merox unit

S/u Diesel

To heavy slop oil tank

To light slop oil tank

Coker consumption

To flare

LLP FlareHeavy cycle gas oil

Light cycle gas oilHP flare

To LPGspheres

To HNUU To LNUU

To ETP

Lean amine

Rich amine

Coker

FGdistributionsystem

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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

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HNNUFeed

LN

Heavy aro. To FO

Ox

Ox + C9A+

C10A to gasoline blending

Xyfrac3 Trains

Iso. 3 Train

Raffinate

Regen cat.

Spent cat.

Cycle max. CCR

Parex3 TrainsC8A+

TolueneTat.

m/u H2 from Plat.

Plat./Rec. Plus/PSA

H2

Debut/PSA gas to FG

LPGH2

Off gas from Tat/Iso

Reformate

M/u H2

from Tat.

Mixxylenesfrom Hazira

Off gasDehp. Off gas to FG

Parex feed

Off gas to FG

Off gasBz.C7A

Light reformate

C9 A

Aromatics

Px

OX frac

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Aromatics

Designed to produce paraxylene and orthoxylene from Naphtha feedstock

and mixed xylenes.

Capacity: Paraxylene 1,200,000 TPA

Orthoxylene 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

• Integrated with FCC unit for feedstock

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Polypropylene

Storage & handling

propyleneethylene

additive Extruder

Reactor

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PolypropyleneDesigned 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