Refining competitiveness

by
Thank
Dr.
Partha You
Maitra
Reliance Industries Ltd.

Singapore

9 th 11th September 2015

Disclaimer
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Industries Ltd. (RIL).

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attracts any liability for any inconsistency or irregularity in terms of the accuracy
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not necessarily to provide any advice or recommendation to the audience/readers. Any
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Reliance Industries Ltd.
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Index
Fundamentals
Crude flexibility
Petrochemical Integration
Conclusion

Refinery competitiveness: Fundamentals

Minimize feed costs

Low crude cost crude flexibility : Sourcing

: Processing
: Quality

Low opex

Maximize product revenues

High value product petrochemical integration

Distillates = Jet + diesel + gasoline

2 mantras for refinery competitiveness

Crude flexibility: Sourcing

Quantity

Process 1358 kb/d of crude (FY15)

Source crude globally

Quality

Refine 144 crude grades from 1999 (16 years)

No constraints on crude properties

Refine 13 new crude grades (FY15)

Refine new crude grades

Virtually any crude grade can be refined

Jamnagar is the destination of choice for novel crude

Eg. Basra heavy (FY15)

Process any distressed crude cargo

Max crude sourcing flexibility

Crude flexibility: Processing

Dilution

Sequencing & Scheduling

Blending

1358 kb/d of crude, large pool for dilution

VLCC = 60 kb/d or 4.4% of crude feed

Suez Max = 45 kb/d or 3.3% of crude feed

Afra Max = 30 kb/d or 2.2% of crude feed

Refine any crude grade by dilution principle

Sequence optimal arrivals of crude grades

Crude scheduling to enable optimal blending

GeCOS system (Shell)

Process crude grades with wide range of qualities

Blend to narrow crude feed window

Minimal variation seen by refinery CDU/VDU

TIS / OMS system (Schneider)

Max crude processing flexibility

Crude flexibility: Quality

API

Sour
Acidic

Metals
Synthetic crudes

From 130 API to 560 API

Peregrino (Brazil) = 13.4API

Ras Gas condensate = 560 API

From 0 to 6.7 wt%

Coban (Guatemala), S = 6.7 %

From 0 to 5.3 TAN

Olende (Gabon), TAN = 5.3 mg KOH

From 0 to 450 ppm Ni + V

Napo (Equador), Ni + V = 450 ppm

From bitumen upgraders

Hamaca (Venezuela)

Cold Lake (Canada)

Max crude quality flexibility

Petrochemical integration: Value Addition

Product

$/t

% of Crude

PX

825-845

198

Propylene

760-780

183

Ethylene

740-760

178

Jet

575-585

138

Diesel

555-565

133

Gasoline

545-555

131

Naphtha

470

112

LPG

460

110

Fuel gas

440

104

Crude

420

Base

Petrochemicals:

Distillates:

Others

Basis = Crude @ $60/bbl

Max value addition to petrochemicals

Petrochemicals integration: Jamnagar refinery

Propylene

Aromatics

ROG Cracker

2 mmt/yr propylene @ 3% of crude

2 FCC @ 420 kb/d

100% captive consumption to PP

Advantage feed = Hydrotreated VGO to FCC

5.45 mmt/yr Aromatics @ 8.1% of crude

2 Platformer @ 190 kb/d

4.2 mmt/yr PX

Advantage feed = Reformate

1.8 mmt/yr ethylene derivatives

2.7% of crude

Advantage feed = Refinery off gas (ROG)

Gasification enabled = Swap SNG for Cracker feed

Maximize margins

Petrochemicals: Propylene
FCC

PRU

PP

2 units, combined capacity = 420 kb/d

Worlds largest FCC (UOP)

Moderate severity, >10% C3= yields

2 mmt/yr of propylene

3 units

C3 splitter design with heat pump (UOP)

6 PP lines, 4 275 kt/yr + 2 450 kt/yr

Combined capacity = 2 mmt/yr PP

Gas phase bulk polymer (Dow)

Worlds largest PP complex

Value addition to propylene + PP

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Petrochemicals: Aromatics
Aromatics

DTA

SEZ/PX-4

Total

CCR reformer, kb/d

90

100

190

PX, mmt/yr

1.9

2.3

4.2

OX, mmt/yr

0.3

0.3

Benzene, mmt/yr

0.4

0.55

0.95

Total Aromatics, mmt/yr

2.6

2.85

5.45

Selective adsorption

Crystallization

3/3

0/1

Crystallizers / Centrifuges

Trans alkylation

Extractive distillation

UOP

BP / Lummus

Operating

Construction

Process
Parex / Isom trains

Licensor
Status
Worlds largest PX complex

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Petrochemicals: Integrated Aromatics

Crude to naphtha to PX @ Jamnagar refinery

PX to PTA to PET @ Dahej

PX to PTA to Polyester @ Silvassa + Hazira

PTA to Polyester @ Silvassa

Integrated polyester value chain

Global #2 in polyester

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Petrochemicals: ROG Cracker

Feed

Product

Extract C2 + C2= from refinery offgas (ROG)

Rich feed = 27% C2= in feed

Substitute C2 + C2= with SNG

Syngas from petcoke gasification produces SNG

SNG substitutes ROG as heater fuel

1.5 mmt/yr ethylene

Coproducts = Propylene + H2

730 kt/yr MEG

400 kt/yr LDPE

650 kt/yr LLDPE

1.8 mmt/yr of ethylene derivatives

MEG = Link in the polyester value chain

Worlds largest ROG Cracker

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Integration
C2 + C2=
H2

MEG
C2 complex

LDPE

Olefins

LLDPE
Syngas/cogen fuel
Petcoke

Crude

H2
Refinery

SNG

Gasification

Future Chemicals

Syngas/cogen fuel

Syngas/cogen fuel

Syngas/new htr fuel

Return
Reformate

PX
PX-4
Benzene

Aromatics

Existing
New

Integration of Refinery + Petrochemicals + Gasification

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Conclusion

Competitive refining

Generate highest value petrochemical products

Integrated refinery + petrochemicals

Process lowest cost crude feed

PP from VGO via FCCs

PX + benzene from naphtha via Platformers
Ethylene from ROG Cracker

Low cost utilities

Recover C2 + C2= to feed ROG Cracker; substitute with SNG

Cogen fuel from gasification for power + steam
H2 from gasification

Innovate or perish

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Thank
ThankYou
You