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    smdtsinoy
    The document provides an overview of the processes at Reliance Petroleum Limited's refinery in Jamnagar, India. It includes block diagrams and descriptions of the key units and their capacities. The refinery has extensive integrated facilities for crude distillation, vacuum distillation, hydrotreating, fluid catalytic cracking, sulfur recovery, coking, aromatics production, and polypropylene manufacturing. The largest units include a 2.25 million barrels per stream day crude distillation unit, a 130,000 barrels per stream day fluid catalytic cracker, and a 400,000 metric ton per year polypropylene plant.

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    Process

    Uploaded by

    smdtsinoy
    302 views30 pages
    The document provides an overview of the processes at Reliance Petroleum Limited's refinery in Jamnagar, India. It includes block diagrams and descriptions of the key units and their capacities. The refinery has extensive integrated facilities for crude distillation, vacuum distillation, hydrotreating, fluid catalytic cracking, sulfur recovery, coking, aromatics production, and polypropylene manufacturing. The largest units include a 2.25 million barrels per stream day crude distillation unit, a 130,000 barrels per stream day fluid catalytic cracker, and a 400,000 metric ton per year polypropylene plant.

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    The document provides an overview of the processes at Reliance Petroleum Limited's refinery in Jamnagar, India. It includes block diagrams and descriptions of the key units and their capacities. The refinery has extensive integrated facilities for crude distillation, vacuum distillation, hydrotreating, fluid catalytic cracking, sulfur recovery, coking, aromatics production, and polypropylene manufacturing. The largest units include a 2.25 million barrels per stream day crude distillation unit, a 130,000 barrels per stream day fluid catalytic cracker, and a 400,000 metric ton per year polypropylene plant.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    302 views30 pages

    Process

    Uploaded by

    smdtsinoy
    The document provides an overview of the processes at Reliance Petroleum Limited's refinery in Jamnagar, India. It includes block diagrams and descriptions of the key units and their capacities. The refinery has extensive integrated facilities for crude distillation, vacuum distillation, hydrotreating, fluid catalytic cracking, sulfur recovery, coking, aromatics production, and polypropylene manufacturing. The largest units include a 2.25 million barrels per stream day crude distillation unit, a 130,000 barrels per stream day fluid catalytic cracker, and a 400,000 metric ton per year polypropylene plant.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 30

    (Mech., Elec., Inst.

    And Civil)
    Reliance Petroleum Limited
    Jamnagar
    Feb98

    PROCESS OVERVIEW

    Contents
    1. 2. Refinery overall block diagram Unitwise details Block diagram Purpose Capacity Technology Salient features

    JAMNAGAR PROCESSES

    Refinery Overall Block Diagram


    Naphtha
    Kerosene Petrol Diesel LPG SBM Crude

    MTF

    CDU/

    VDU

    FCC Propylene Coker Sulfur

    Aro PP

    PX
    PP Power
    4

    MPP

    Captive Power Plant (Power & Steam)


    Air Fuel Steam

    CC Compressor

    HRSG 3 ph. power

    GT
    Aux. Boiler

    HHP LP Condensate MP

    HP 3 ph. power STG

    Nitrogen generation
    Vent gases Molecular sieves Expander

    N2

    ADU
    Liq.N2

    Liq. O2
    Air compressor Super cooler O2

    Sea water intake system


    Chlorination chamber Stop gate Cl2 Filtered sea water reservoir

    Fire water pond To RTF


    FW network

    Intake channel

    Stop Stilling gate basin

    Filter Fire water reservoir Desal water

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

    Desal unit Outfall point 7

    Multi Effect Distillation


    Ejector system
    Vapor Vapor Vapor

    Condenso

    Fresh sea

    water Steam 1 2 11

    Brine discharge

    Steam condensate

    Distillate

    Distillate

    Distillate

    Power & utilities


    GTG STG HRSG AUX. BOILERS 6 x 30 MW 4 x 30 MW 6 x 125 T/hr 4 x 125 T/hr Total installed cap: 1,250 T/hr Total installed cap. : 300 MW

    Utilities (All units in m3/hr)


    Design Sea water Desalination Demineralisation 7,000 2,000 1,340 Normal 4,468 1,569 694

    CT-1
    CT-2 CT-3

    23,310
    23,310 23,310

    12,849
    17,440 19,739

    CT-4
    Air ( Nm3/hr ) Nitrogen ( Nm3/hr )

    23,310
    100,000 20,100

    17,838
    79,913 13,969
    10

    CDU/VDU
    Sat. Gas Conc Unit
    Crude Desalters CDU

    C3/C4 ( To LPG Merox) Naphtha to hydrotreater Light Kerosene Heavy kerosene Diesel
    HAGO

    Fired heater

    VDU

    Vacuum Gas Oil to FCC Unit

    Vacuum residue to delayed coker

    11

    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.
    12

    Hydrotreater
    M/u H2 Recycle gas Diesel VGO LN Reactor To waste water system
    13

    Ovhd. condensor

    Offgas to SGCU

    Diesel Product separator Stripper VGO LN

    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 14 BPSD)

    FCC
    Flue gas Process air BFW Power Recovery Train Reactor vapors Steam Spent catalyst

    O/H gases
    Treated gas LPG

    M/u catalyst
    Regenerator Process air

    Reactor
    Regen. catalyst

    Main Unsat column Heavy gas conc. naphtha

    Gasoline
    LCO

    Steam Raw oil

    Fuel oil

    Naphtha

    15

    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.
    16

    Merox
    Feed LPG Rich amine Reactor

    Extractor

    ATU
    Lean amine

    Caustic Sweet KOD LPG

    Caustic makeup

    To ETS

    Feed

    Air mixer

    Reactor

    Caustic settler

    Sweetened Product

    Caustic

    Air

    Catalyst

    To ETS
    17

    Merox
    Purpose is to remove inherent organic sulfur from LPG, Kerosene and Gasoline. Capacity: Unsat LPG Merox Sat LPG Merox Kero Merox Gasoline Merox 60,000 BPSD 19,000 BPSD 70,000 BPSD 50,000 BPSD

    18

    SHP/TAME
    Off gas Raffinate C5 feed Pentene column H2 SHP Reacto r TAME Reactor

    Strippe r

    TAME

    19

    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 : TAME : UOP,USA (licensor) Salient features: TAME is an octane no. booster
    20

    660 KTPA 210 KTPA

    Hydrogen
    H.P BFW
    Recycle H2 Steam generator HP Steam export Shift & gas cooling Product H2

    Refinery Feed fuel gas gas compr. Natural gas LPG Main pumping section

    Steam Feed purification reformer

    Gas purification

    Refinery general fuel gas

    Waste gas

    Naphtha (future)

    21

    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
    22

    Sulfur
    Acid gases from ARU Thermal reactor

    Claus reactor

    CBA reactor

    Air Condenser 1
    Sour gases from WWSU Condenser 2

    Condenser To tail gas 3 incinerato

    Liquid sulfur degassing pit

    To sulfur granulation unit


    Air

    23

    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
    24

    Coker
    Heavy cycle gas oil LLP Flare Light cycle gas oil HP flare To HNUU To LNUU Unsat gas To LPG conc. unit Unsat LPG spheres Coker Merox unit FG To flare distribution Coker consumption system Rich amine To light slop oil tank Lean amine To heavy slop oil tank To ETP
    25

    Vacuum residue tank

    FO tank

    S/u Diesel Coke handling system

    Amine treating

    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

    26

    Aromatics
    LPG Debut/PSA LN H2 Regen cat. gas to FG H2 Spent cat. Plat./Rec. Plus/ Feed HNNU PSA Cycle Off gas Bz. max. C7A from Tat/Iso Off gas CCR Reformate Light Toluene Parex Px reformate Tat. Raffinate Off gas 3 Trains C8A+ Parex Dehp. Off M/u H2 m/u H2 feed gas to FG from Tat. Ox + C9A+ from Plat. C9 A Xyfrac Iso. Ox Mix OX frac 3 Trains 3 Train xylenes C10A to Heavy aro. from 27 gasoline To FO Hazira blending Off gas to FG

    Aromatics
    Designed to produce paraxylene and orthoxylene from Naphtha feedstock and mixed xylenes. Capacity: Paraxylene 1,200,000 TPA

    Orthoxylene
    UOP, USA (licensor) Salient features:

    150,000 TPA

    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
    28

    Polypropylene

    Reactor propylene ethylene additive Extruder

    Storage & handling

    29

    Polypropylene
    Designed 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
    30

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