Louis Alfred L.

Mendros 15-52058
PetE- 5203 March 03,2020

Company Background

The Jamnagar manufacturing division is the world's largest refining hub. The
entire refining complex was built in a record time at globally competitive capital costs –
in fact, at costs much lower than comparable refineries around the world. Its scale,
design, flexibility, level of automation and degree of integration heralded the way
refineries of the future would be built. The speedy growth of the complex lies at the
heart of India's transformation. It has transformed India from being a net importer of
petroleum products to a net exporter, thereby ensuring the nation's energy security.

With crude processing capacity of 1.24 million Barrels Per Stream Day (BPSD),
the Jamnagar refinery is a trendsetter and has won several awards, including the
prestigious 'International Refiner Of The Year' award. It also enjoys the distinction of
housing some of the world's largest units, such as the Fluidized Catalytic Cracker
(FCC), Coker, Alkylation, Paraxylene, Polypropylene, Refinery off gas (ROG) cracker
and Petcoke gasification plants.

Fuels from Jamnagar refinery are exported to several countries across the world.
This complex refinery is future ready and can produce gasoline and diesel of any grade.
Reliance also has another refinery – the sixth largest in the world – in the Special
Economic Zone at Jamnagar. This refinery has a capacity for processing 580,000 BPD
of crude.
 Process Flow Diagram for Integrated Gasification Combined Cycle

Integrated Gasification Combined Cycle (Petcoke Gasification)

IGCC means Integrated Gasification Combined Cycle. The gasification is partial

oxidation of coke with O2. Coke gasification reaction converts coke into syngas. The
primary constituents of syngas are CO and H2. Syngas can be a gas turbine fuel, which
can produce power in a combined cycle. Syngas can produce hydrogen and other
chemicals, such methanol and acetic acid.

The major elements or processing sections for the IGCC project are:
• Feed preparation
• Gasification
• Effluent handling
• Sour block
• Air Separation Unit (ASU)

Feed preparation
Coke shall be transported by a fully enclosed conveyor, to minimize dust, from
the existing coke hoppers to the IGCC plot area. The coke shall be stored in coke
storage silos. The flux shall be transported by trucks and stored in flux storage silos.
Coke and flux, in the proper ratio, shall be weighed. Coke particles shall be reduced to
proper size by grinding. Coke and flux shall be fed to the gasifier either in the form of a
slurry or as dry feed. In slurry feed, coke slurry is pumped. In dry feed, coke particles
are
pneumatically conveyed with nitrogen. Oxygen is supplied from an Air Separation Unit
(ASU) to the gasifier.

Gasification

Petcoke feed goes to the gasification section. There will be several gasifier trains.
In the gasifier, the petcoke is mixed with oxygen in a specially designed feed injector.
The oxygen deficient atmosphere inside the gasifier vessel generates syngas at an
average temperature 1425°C. Temperature fluctuations are in the range of +/- 25oC.
The operating range of the petcoke gasifier is 1400 – 1450oC. The fluctuations are due
to normal variations in the petcoke feed flow to the gasifier. Such flow variations in the
solid handling are normal and are always expected. As the partial oxidation reaction is
exothermic in nature, variations either in the petcoke feed or oxygen reflects in variation
in the gasifier temperature. The temperature is controlled automatically by adjusting the
oxygen flow to the gasification reactor. Audio visual alarm indication is always available
in case the temperature variation is beyond preset values. If required the control can be
done by manual operation as well. The raw syngas from the gasifier consists primarily of
CO, H2, CO2 and H2S with minor amounts of other compounds. The fluxant
concentrates the ash and minerals in the petcoke to form a molten slag. The syngas is
cooled by raising high pressure steam and is further cooled in a quench chamber. The
by-product slag exits the quench chamber through a lock hopper.

Fly Ash Disposal

The ash content in the Petcoke is less than 0.5%. The fluxant is added in the
feed preparation section captures the ash in the petcoke and forms a molten slag in the
gasification section. When the syngas is cooled in the quench section the molten slag is
solidified into glassy beads. There is no generation of fly ash from this process. These
beads will be disposed off in the secured landfill facility. The feasibility of recovering
metals from these beads will also be pursued

Effluent handling

In effluent handling, slag is cooled and slag and water are separated. Slag is an
IGCC by-product. Waste water is recycled to the extent possible and the remaining is
sent to the effluent treatment plant.

Sour block

In the sour block, the raw syngas shall be cooled and scrubbed. Then acid gases
– H2S and CO2 – present in the syngas, are removed by amine scrubbing. It is
estimated that for an annual petcoke consumption of 8750 KT with average sulphur
content of 7.5%, the total flow of amine solvent is estimated at 5700 m3/hr. The
syngas used for
petrochemicals must have low CO2, because CO2 is a diluent. Hence a second stage,
smaller amine absorber, with a stronger amine, shall be employed as a scrubbing
medium to preferentially remove CO2 from the syngas before routing it to the
petrochemical users. The amine is regenerated in a regenerator column using LP steam
as the reboiler medium. The condensate is sent to an ammonia stripper for ammonia
removal. The collective acid gas streams shall be fed to the Sulphur Recovery Unit
(SRU) where the streams shall be processed and the liquid sulphur collected in the
sulphur condensers and in the tail gas coalescer drains by gravity into a sulphur pit. The
required SRU capacity is for 1300 TPD of liquid sulphur. From environmental
considerations, the IGCC project shall have a Tail Gas Treating (TGT) unit at the back-
end of the SRU. The Tail Gas Treatment process is incorporated to further treat the flue
gases and reduce the SO2 emissions. The TGT process treats the flue gases from the
Sulphur Recovery Units (SRU) to convert the sulphur in the flue gas to elemental
sulphur. The SRU operates with the advanced Clause and Cold Bed Adsorption process
at an efficiency of +99%. With the TGT following the SRU, the overall efficiency would
be enhanced to 99.9%. By reducing the SO2 emissions, TGT helps in reducing the
impact on the environment.

Details of TGT Treatment

In the petcoke gasification section the sulphur present in the petcoke is converted
to H2S because of the low oxygen availability. In the sour block, the raw syngas shall be
cooled and scrubbed. Then acid gases – H2S and CO2 – present in the syngas, are
removed individually by amine scrubbing. The amine is regenerated in a regenerator
column using LP steam as the reboiler medium and recycled. The H2S stream shall be
fed to the Sulphur Recovery Unit (SRU) where the streams will be processed and the
liquid sulphur collected in the sulphur condensers and in the tail gas coalescer drains by
gravity into a sulphur pit. The SRU operates with the advanced Clause and Cold Bed
Adsorption process at an efficiency of +99%. With the TGT following the SRU, the
overall efficiency would be enhanced to 99.9%. By reducing the SO2 emissions, TGT
helps in reducing the impact on the environment The Tail Gas Treatment process is
incorporated to further treat the tail gases and reduce the SO2 emissions. The SO2
present in the tail gas is converted to H2S in the presence of H2 in a catalytic reactor.
The outlet from the reactor is cooled and amine washed to remove the H2S. These
gases are then sent to an online incinerator to burn off the residual H2S (<100 ppm)
before release into atmosphere through a tall stack. The amine rich in H2S is
regenerated for reuse while the released H2S is sent to the SRU feed.

Air Separation Unit (ASU)

The IGCC project shall have multiple ASU trains. The ASU scope shall include
liquid oxygen vaporizers for emergency supply. The N2 available from the ASU can be
added as diluents in the syngas to moderate the flame temperature in the gas turbines
and reduce the NOx emissions. A process block diagram for the IGCC unit is presented
in the figure.

Air Emissions:

The SO2 & NOx emissions from the coke gasification process are 0.083 and 0.012 TPH

respectively.

Liquid effluent:

The estimated wastewater generation is 150 M3 /Hr (Can be recycled in the feed
preparation)

Solid waste:

The estimated solid waste generation from the coke gasification process will be 0.37

MM TPA