Reliance Industries Limited, Jamnagar

The Jamnagar manufacturing complex is a fully integrated manufacturing complex, with

a petroleum refinery complex, an aromatics/petrochemical complex, a power generation
complex, a port and terminal complex, as well as access to a pipeline network.

The Jamnagar complex primarily consists of a 33 million tonnes per annum refinery that
is fully integrated with downstream petrochemicals units, which manufacture naphtha-
based aromatics as well as propylene- based polymers.
Fully equipped with facilities for meeting the captive energy requirements in the form of
power and steam, the complex is well supported by world-class logistics.

Refining processes
The refinery complex at Jamnagar consists of more than 50 process units which together
process the basic feedstock, crude oil, to obtain various finished products deploying the
following major refining processes:
 Crude oil distillation (Atmospheric as well as vacuum distillation)
 Catalytic cracking (Fluidised Catalytic Cracker )
 Catalytic reforming (Platforming )
 Delayed Coking

PROCESS DETAILS

The refinery processing units include Primary Process Units, namely Atmospheric and
Vacuum distillation units and secondary process units like Fluid Catalytic Crackers (FCC),
Delayed Coking Units (DCU) etc.

The Refinery has the following processing Complexes:

Crude Complex includes two streams of primary crude atmospheric and vacuum distillation
facilities (CDU and VDU).

Vacuum residue from the crude complex undergoes secondary conversion in a Delayed
Coker, included in the Coking Complex.

Fluid Catalytic Cracker (FCC) is the principal conversion unit for fuel and petrochemical
(Olefin) products.

The Olefins present in the cracked products from the FCC is recovered in the Olefins
Complex - Propylene Recovery & SHP/TAME Unit

Alkylation Complex (Alky) is unit producing high value Alkylate product by mixing olefins
from Unsat LPG and the iso-butanes from Sat LPG. Shortage of iso-butanes is fulfilled by
converting n-butanes in Butamer Unit. Sulfuric Acid used as catalyst in Alkylation reaction,
is regenerated in Spent Acid Regeneration Unit (SAR).
The Hydro-treating Complex (two streams for Diesel and two streams for vacuum gas oil))

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includes Hydro-processing of various streams for superior product yields and qualities with
low Sulphur.

Two Hydrogen Manufacturing Units is also included to supply Hydrogen gas required for
Hydro-processing which handles sulfur in the crude.

Merox treating units for the removal of sulphur compounds from LPG (three units),
Gasoline (two units), and Kerosene (two units) have been provided. A light naphtha hydro-
treating unit is included to remove sulphur from Naphtha produced in Coker.

The Aromatics Complex includes Continuous Catalytic Regeneration (CCR) Reformer and
Downstream Extraction Units (three streams of Parex units, two streams of Tatoray units
and an extractive distillation unit)) to make Paraxylene, Benzene, and Orthoxylene.

Amine Treatment Unit (ATU-four streams)) complex treats rich amine from individual
amine adsorption units from CDU, FCC, Coker, VGOHT, DHT, HNHT, LNHT. Stripped acid
gases are sent to sulphur recovery unit.

Sour water stripping complex includes two units of phenolic Sour Water Stripper (SWS)
and tow of Non-phenolic SWS. Stripped Gases are sent to sulphur recovery unit.

Three streams of Sulphur Complex produces product Sulphur extracted from the fuel
products.

Propylene is polymerized in Polypropylene Unit (three lines) to produce polypropylene

pellets

Offsite facilities include captive power and steam generation plants, Utilities plant for
supply of water and air and tank farms for storing raw materials and products.

1. Crude Complex

 Crude Distillation Unit (CDU)

Crude Oil from offsite storage tanks is fed to the unit by Crude Feed Pump. The special
design enables this crude feed at ambient temperature to pick up heat from product and
pump around streams in the crude preheat exchanger train.

At an intermediate stage during the preheating, crude oil is treated for removal of
contained salts by passing it through an Electrostatic Crude Desalter. After desalting,
crude is further heated in the exchanger train.

Stripped water obtained from the Sour Water Stripper Unit is used for desalting purpose.
Effluent Water from desalter is sent to Wastewater Treatment Plant specially designed to

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treat high TDS wastewater (HTDS-ETP).

Preheated crude is fed to Atmospheric Furnace, which is a fired heater. Heated and
partially vaporized crude from the furnace enters the Atmospheric column at the flash
zone. The Atmospheric Column is equipped with requisite as well as circulating refluxes.
The overhead vapor from column is condensed and the condensed liquid consisting of
hydrocarbon and water is collected in Overhead Atmospheric Column Reflux Drum, which
also acts as a settler to separate out the hydrocarbon and water. Hydrocarbon stream
consisting of all the fuel gas, LPG, and naphtha components is pumped to Naphtha
Stabilizer after preheating in the Stabilizer Feed/Bottom Exchanger.

Three side stream products – Heavy Naphtha, Kerosene and Diesel are drawn from the
atmospheric column after stripping off the light ends in heavy naphtha, kerosene and
diesel strippers. Kerosene and diesel product after preheating the crude in preheat train
exchangers are further cooled to rundown temperatures.

Reduced Crude Oil (RCO) drawn off from the bottom of Atmospheric Column is pumped to
the Vacuum Furnace of Vacuum Distillation Unit. Atmospheric column is provided with
necessary pumps around streams for optimum vapor/liquid internal traffic and heat
recovery. The pumps around streams are used to preheat the crude in the preheat
exchanger train.

Stripping steam is injected at appropriate places to strip off the light ends of the respective
products. Overhead naphtha is stabilized in Naphtha Stabilizer. Naphtha stream from
atmospheric column reflux drum is pumped to stabilizers Feed/Bottom Exchanger for
preheating by exchanging heat with the hot stabilized naphtha stream obtained as bottom
product from stabilizer. Re-boil heat is supplied by appropriate heating medium.
Stabilized naphtha obtained as the bottom product exchanges heat with cold feed in
exchanger and is then routed to its destination by operating pressure after heat exchanger
and cooling.

Overhead vapor from stabilizer is partially condensed. The uncondensed vapor goes to
the ultra low sulfur Fuel Gas System of the complex. A part of the condensed liquid is
used as reflux to the column and the other part of the condensed liquid is pumped as LPG.

 Vacuum Distillation Unit (VDU)

Reduced Crude Oil (RCO) from atmospheric column is routed to the Vacuum Furnace,
which is a fired heater. Heated and partially vaporized RCO enters the flash zone of
Vacuum column. The Vacuum gas oils are drawn from the feed to either HCU or FCC or
Once through Hydro-cracker. The Vacuum gas oil streams and pumps around are used to
preheat the crude in the preheat exchanger train. The vacuum products are cooled by
exchanging heat to crude in the crude preheat train. They are further cooled to rundown
temperature in coolers.

Over head vapor from vacuum columns goes to the vacuum system comprising of steam

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jet ejectors. The effluent from the condensers is collected in Hot well. The recovered slop
oil from hot well is pumped to slop tanks while the sour water from hot well is pumped to
sour water stripper unit.

 VGO Hydro-treating/ Once-through-Hydro-cracking Unit

This unit is designed for hydro-desulphurisation of vacuum gas oil produced in the Vacuum
Distillation Unit into feed to the FCC. Additionally there will be some cracking into middle
distillates. The unit shall have the flexibility to go for maximum hydrotreating mode to a
conversion mode which is termed as the once-through-hydrocracking. The feed can be
either hot from the Vacuum Distillation Unit or cold from the Tank. It is preheated with
reactor effluents, mixed with make-up and recycle hydrogen and heated in a furnace and
then introduced into the reactors. Here Vacuum Gas Oil is subjected to treatment/cracking
over catalyst beds in the presence of hydrogen at high pressure and temperature. The
reactor temperature is controlled by using cold recycle gas as quench in between two beds
of catalyst. Reactor effluent, after preheating the feed and getting further cooled in air
coolers, is fed to the high pressure separator where gas separates out, which is
recompressed and recycled back to the reactor inlet. Separated liquid is further flashed in
low pressure separators where dissolved gases separate from the liquid.

Liquid product is then fed to a conventional fractionating section where Gas, LPG, Naphtha
and Gas Oil are drawn as products. The unconverted bottoms are sent to FCC unit as
feed stock.

Gases from the unit are treated for the removal of hydrgen sulfide in Amine Absorbers.
Naphtha from this unit combines with the straight run naphtha. Sour water Stripping Unit is
provided for removal of ammonia, hydrogen sulfide and dissolved gases.

2. Fluid Catalytic Cracking Unit (FCC)

Vacuum gas oil from VDU and Coker Gas from DCU will be hydrotreated to remove sulfur
and then catalytically cracked in the Fluid Catalytic Cracking Unit. Feed stock will be
cracked over a hot stream of Fluidised Catalyst to product Gas, LPG, Gasoline, Cycle oil
and Clarified oil. The FCC Unit mainly consists of (i) Reactor / Regenerator Section, (ii)
Fractionation Section and (iii) Gas Concentration Section.

a. Reactor / Regeneration Section

The fresh feed enters the unit from either the VGO-HT Unit or storage. Slurry oil
(catalyst bearing oil) from the Slurry Settler is recycled along with the fresh feed is
contacted with hot regenerated catalyst at the bottom of the reactor riser pipe.
The oil is vaporised by hot catalyst and the resultant vapors carry the catalyst
upward through the riser with a minimum of back mixing. The desired cracking
reaction takes place mainly in the riser, and the catalyst is separated from the
hydrocarbon vapours at the top of the riser pipe, to minimise secondary reactions.
The reactor cyclone separator remove most of the entrained catalyst from the oil

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vapors. The oil vapors carrying minor quantity of catalyst are fractionated in the
fractionation section.

The cracking reaction lays down coke on the catalyst and the catalyst thus spent
is stripped off the oil using steam. The spent catalyst, after stripping, passes into
the regenerator in which the coke is burnt, oxygen being supplied by an air blower.
The regenerated catalyst flows downward into the reactor riser to complete the
cycle. The regenerator shall be designed in complete combustion mode,
eliminating the need for a CO boiler. The flue gas leaving the regenerator is
utilised in generating steam and in a power recovery turbine to recover energy.

b. Fractionation Section

The main fractionator column is of conventional design, taking full boiling range
naphtha over head and cycle oil as a die cut. The fractionator bottoms product is
sent to a slurry settler and the resulting clarified oil will form a component for
blending into internal fuel oil supply with low sulfur contact.

c. Gas Concentration Unit

The uncondensed gases are compressed, cooled and charged to an absorber

which employs cracked gasoline to absorb the light ends. Any gasoline carryover
is trapped in a sponge absorber which uses light cycle oil as the absorbing
medium. Rich gasoline from absorber is stripped off its lighter ends in a reboiled
stripper. Ethylene is recovered from the FCC light-end gases via a ethylene
recovery unit. A part of the LPG is taken out as propylene from the propylene
splitter. Another boiling point cut goes to depentanizer to remove C5 for Tertiary
Amyl Methyl Ether (TAME) unit. After the Depentanizer, top stream goes to TAME
which is partly used for improving the quality of the gasoline pool after Merox
treatment and the heavy Naphtha form the splitter goes to Heavy Naphtha
Hydrotreater of Aromatics Complex.

3. Delayed Coker Unit (DCU)

In the delayed coking process the heavy residual feed stocks are heated to their coking
temperature and the resultant mixture is allowed to stand for long periods of time in large
insulated vessels called coke drums.

During this time, the feed stock undergoes pyrolitic polymerisation and the thermal
decomposition of high molecular weight compounds. Coke is formed by two different
mechanisms under these high temperature conditions. In one, the colloidal suspension of
the asphaltene and resin compounds is distorted resulting in the precipitation of the
compounds to form a highly cross-linked structure of amorphous coke. The compounds
are also subjected to a cleavage of the aliphatic groups. Coke formed from these resin-
asphaltene compounds is undesirable for the manufacture of high grade coke.

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The second reaction mechanism involves the polymerisation and condensation of

aromatics, grouping a large number of these compounds to such a degree that coke is
eventually formed. The coke produced from these compounds is the most suitable
premium grade needle coke. Whereas the polymerisation and condensation products are
separated as coke in the coke chamber, the other products are separated into distillate
fuels in a fractionator.

Short Residue from Vacuum Distillation Unit is feed stock to this unit. It is preheated in a
heat exchanger train and along with the recycle stock is heated to the coking temperature
about 500 deg C, which produces partial vaporization and mild cracking. The vapour liquid
mixture then enters the coke chamber which is in coking service, where the vapour
experiences further cracking as it passes through the coke chamber and the liquid
experiences successive cracking and polymerization until it is converted to vapour and
coke. The unit has two coke chambers one in coking service while the other is being
decoked with high pressure water jets.

4. Aromatics Plant

The Aromatics plant is divided into the following sections:

i) Naphtha Hydrotreater Section

This process is a catalytic process employing a selective catalyst and a Hydrogen

gas stream to decompose organic sulphur, oxygen and nitrogen compounds
contained in the naphtha feed.

This process is used to remove platforming catalyst poisons from the naphtha prior
to charging to Platforming section.

ii) Platforming Section / CCR

This section processes low aromatic Naphtha into high aromatic Naphtha. The
feed to the reformer is hydrotreated Naphtha. The catalytic reformer consists of a
reactor section, a net gas compressor and a continuous catalytic regeneration
section.

CCR : This section of the platforming unit allows the refiner to operate the reactor
section at high severities by continously regenerating a circulating stream of
catalyst form the platforming reactors.

iii) Xylene Fractionation Unit

The function of this is to prepare feedstocks for Parex and Tatoray. It consists of 2
distillation columns. The overheads from the column is a C 8 aromatics rich cut
which is the feed to the parex unit. The bottoms are directed to the orthoxylene
splitter to recover orthoxylene. The bottom from this goes to Heavy, C 9 column

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which converts the heavies into a C9 overhead for the Tatoray unit and heavy C 10+
stream to be used as fuel in the Refinery.

iv) Parex

PAREX is a adsorptive separation method for recovery of high purity Paraxylene

from C8 Aromatic Fractions from the overhead of the Xylene Column. It uses a
solid adsorbent; a Zeolite material; a liquid desorbent PDEB and a flow directing
device called Coplnar Manifold Index or CMI. The Paraxylene produced is
>99.5% pure. The process can economically recover 92-94% of PX in a single
pass.

v) Tatoray

This is a catalytic process for transalkylation of aromatics. The major Tatoray

reaction, C9 aromatic disproportion action and transalkylation with toluene yield
Xylene. Toluene and mixed C 9 aromatics can be convereted to C 6, C8 and C10
aromatics.

vi) Isomar

This is a catalytic isomerisation process to efficiently convert mixture of C 8

aromatics to a near equilibrium mixture. It is used to convert Metaxylene and Ethyl
Benzene to Paraxylene and Orthoxylene. In this process, slight amount of
Toluene is also produced. The catalyst is a bifunctional noble metal spherical
catalyst containing both acid and metal sites.

5. Alkylation Complex

Alkylation is a stirred auto-refrigerated process using sulfuric acid as a catalyst.

The reaction occurs at a low temperature (@ 1-6 0C) and low pressure (0.65
kg/cm2). The unit consists of the following sections:

a) Diolefin saturation (DIOS) where the diolefins in the Unsat. LPG are
removed by saturating with hydrogen in DIOS Reactor (catalyst is Palladium on
alumina base. This is required as diolefins in Alkylation feed leads to high acid
consumption and fouling problems downstream. The Reactor effluent is stripped
of lighters and hydrogen in a DIOS Stripper.

b) Alkylation feed preparation: The olefin feed is mixed with iso-butane from
Sat. LPG and divided to pass through four parallel trains of coolers, chillers,
filters and coalescers before entering the reactors.

c) Reaction and Auto-refrigeration section, in which the feed from the four
trains is further split in two to reach eight reactors, two reactors per train. Each
reactor has twelve agitators to ensure proper mixing of the feed with sulfuric acid

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as a catalyst, which also enters individual reactors. The Alkylate formed in the
reactors flows to the settlers having three compartments, the primary settler, the
secondary settler and the accumulator. The heavy spent acid from the accumulator
goes to the spent acid storage. The lighter Alkylate undergoes caustic wash and
water wash to remove acid traces before entering the fractionation section. The
fractionation section is basically to separate out lighters like propane and n-
butane (to storage), isobutane (recycled to reactors) from Alkylate. The pressure
and temperature of the reaction is controlled by operation of Refrigeration
Compressor.

d) Butamer Unit: This section acts as a backup for iC 4 provision to the

Alkylation section. The nC4 obtained from Debutaniser column overhead is fed to
the Butamer where its isomerization to iC4 occurs and then this product is fed to
the DIB. The section consists of: Hydrogen makeup gas driers and butane feed
driers – To ensure no moisture enters reactors due to high sensivity of catalyst to
moisture. Butamer Reactor Section - Isomerization of nC 4 to iC4 in two reactors in
series in chlorided atmosphere. Stabilizer and Off gas scrubber Section – iC4
from the reactor outlet is separated from lighters in the Stabilizer and sent to
Alkylation section. The acidic nature of the lighters is neutralized by scrubbing
with caustic solution and the lighters sent to fuel gas header.

e) Spent Acid Regeneration Unit: For the Alkylation reaction to proceed, the
sulfuric acid used as a catalyst has acid strength of 99.2 %. Subsequently, as the
reaction proceeds, its concentration drops and the acid has to be regenerated at 88-
90 % strength to bring it back to 99.2 % for recycling it to the reactors. The
catalyst in Converter is a combination of Sodium, Potassium and Vanadium salts
on alumina support. The section comprises of Combustion Chamber Section -
Spent SA broken down to SO2, H2O and some SO3. Purification, Cooling and
Drying Section - Removal of H2O and SO3 to dry and cool SO2 for conversion
downstream. Conversion Section – Conversion of SO2 to SO3 in a Catalytic
Converter. Absorption Section - Absorption of SO3 in sulfuric acid to maintain the
concentration of acid at 99.2 %.

6. Light Naphtha Hydrotreating Unit

The feed naphtha is mixed with recycle hydrogen gas and sent through feed/effluent
exchanger, where it is heated with outgoing reactor effluent. The partially heated feed is
then brought to reaction temperature in the heater and is fed to a fixed bed catalytic
reactor. Essentially sulfur removal from the feed is by converting it to H 2S in the reactor
system. The reactor effluent after giving heat to incoming cold feed is condensed and
flashed in a separator. The gas separated here is compressed and mixed with make-up
hydrogen from reformer unit and recycled back to the reactor. A small stream of separator
gas is withdrawn before compression as purge gas to avoid build-up of impurities such as
methane, ethane etc. in the recycle gas hydrogen stream. The liquid from the separator
after exchanging heat with outgoing bottom product of stripper is fed to the top of the
stripper column. Both hydrogen sulfide and water are separated from it at the stripper

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overhead system. The sulfur bearing off-gas is sent for H 2S removal while water collected
in reflux drum is withdrawn periodically. The desulfurised and stripped naphtha, obtained
in bottoms of stripper after passing through feed/bottom exchanger is sent to catalytic
reforming unit.

7. Hydrogen Manufacturing Unit

This unit is designed to produce 99.9% purity hydrogen.

Hydrogen is produced by steam reforming of Naphtha. Naphtha is first desulphurised over

a desulphurisation catalyst where, in the presence of hydrogen, non-reactive sulphur
compounds are hydrogenated to hydrogen sulphide which is then absorbed on zinc oxide
beds. The desulphurized feed is mixed with preheated steam, heated to the desired
temperature and passed into steam reforming furnace tubes containing a nickel based
catalyst. The hot reformed gases leave the tubes and after exchanging heat to generate
steam, pass through a CO shift converter where the carbon monoxide is reacted with
excess steam to produce additional hydrogen and carbon dioxide. The converted gases
leave the reactor and preheat the incoming Naphtha, Boiler Feed Water and
Demineralized water. The hydrogen is purified to remove inert gas impurities on molecular
sieves in PSA (Pressure Swing Absorption) system. All absorbed gases are removed
during desorption and regeneration of the beds and used as reformer fuel.

8. Merox Treating Units

Merox treating units for the removal of sulphur compounds from straight run LPG, FCC
LPG, Gasoline, and Kerosene have been provided. All these units remove mercaptans
from the liquid streams and mercaptans from the LPG.

LPG is first washed with dilute caustic solution and then mixed with air and passed over an
alkaline catalyst bed where mercaptans, oxidised to disulphides are absorbed.

The kerosene stream is pre-treated in a coalescer where it is given a dilute caustic wash
and then mixed with air and passed over an alkaline catalyst bed to remove mercaptans.
The reactor effluent goes to a caustic settler where caustic solution is separated and
recirculated. The product is post treated by water washing, and filtered through salt and
clay towers before being sent to storage.

After a caustic pre-wash, gasoline is then post treated by sand filtration and sent to
storage. In each unit the alkalinity of the catalyst in reactor is restored by periodic
recirculation of caustic which also washes off contaminants accumulated in the bed.

8. Diesel Hydro-treaters / Hydro-desulphurization Units

The gas-oil feed is charged to the unit through a pump. The make-up hydrogen coming
from the H2 plant is compressed and mixed with recycle gas from compressor. The gas-oil
feed is then mixed with the recycle and make-up gas from the compressors. The mixture
constitutes the reactor feed and is heated in a heat exchanger exchanging heat with the

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reactor effluent. Finally, the reactor feed is heated to the desired reaction temperature in
the furnace and charged to the reactor.

The desulphurisation reaction occurs in reactor. The reactor effluent is split into two parts.
One part is used to heat the stripper feed. The other part is used to preheat the reactor
feed. The reactor effluent stream is further cooled in heat exchangers.

The reactor effluent is next flashed in the high pressure separator. A major part of the
vapor from the pressure separator constitutes the hydrogen recycle gas which is circulated
to the reactor by the recycle gas compressor. The rest of the vapor from high pressure
separator is sent to the Amine Absorption Unit.

The liquid from the high pressure separator is preheated in heat exchangers by
exchanging heat with the stripper bottom and then with a part of reactor effluent and finally
fed to the stripper.

The stripper overhead is partially condensed in the air cooler and water cooler. Part of the
liquid distillate from reflux drum is pumped to stripper as reflux and rest goes out as
naphtha product.

The uncondensed vapor is sent to the Amine Absorption Unit for sulfur recovery. The re-
boiling heat to stripper is provided by the stripper steam introduced at the bottom.

The bottom product from the stripper is the de-sulphurised gas oil product. It is cooled in
the air cooler, the water cooler and passes though the vacuum driers/ coalescer drums to
remove moisture before it finally goes to the storage.

9. Amine Treating Unit

Fuel Gases, rich in hydrogen sulfide from various units are scrubbed with Methyl Diethanol
Amine (MDEA) Solution, which absorbs hydrogen sulphide. One absorber is provided for
the VGO Hydrotreater/ Once-through-hydrocracker Unit because of the high hydrogen
sulphide content of the gases produced. Another absorber removes hydrogen sulfide from
gas streams collected from other units. The rich amine solution from both absorber is sent
to a single Regeneration system for regeneration of Diethanol Amine.

Acid rich fuel gases enter the bottom of the Amine absorber column while lean Amine
solution enters from the top. As the gases move up the column they are washed off by a
counter current stream of amine solution which selectively absorbs hydrogen sulfide from
the gas stream. Sweet fuel gas leaves the absorber from the top and goes to the fuel gas
system. Rich amine solution leaving the absorber from bottom is heated by incoming hot
regenerated amine and routed to Amine generator via flash drum. Rich amine enters the
Regenerating Column from the top. A column bottom stream is circulated through a Kettle
reboiler where it is heated with steam and the vapours are fed below the bottom tray of
regenerator. Overheads of the column containing acid gases are cooled and collected in a
reflux drum. Acid gases are drawn from the column and routed to Sulfur Recovery Unit.

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10. Sour Water Stripping Unit

Sour water coming to the unit is received in sour water surge drum where any flashed
vapour and hydrocarbon liquid carryover is separated. The flash vapour is sent to
hydrocarbon flare and hydrocarbon liquid is skimmed off and sent to OWS.

The sour water is pumped from surge drum by sour water stripper feed pump, preheated
by feed/bottoms exchanger and then introduced to sour water stripper. The H 2S and NH3
from sour water are stripped off and leave from top and are routed to Sulfur Recovery Unit.

The stripped water leaving the column passes through feed/bottoms exchanger. Then it is
pumped by stripped sour water through stripped water cooler to the Effluent Treatment
Plant. LP steam supplies heat to sour water stripper reboiler.

11. Sulfur Recovery Unit

Acid gas from the Amine Regeneration Unit enters acid gas knockout drum from which it
flows to main burner. Entrained amine from the acid gas is collected and recovered from
the bottom and is taken to amine sump.

Acid gases containing H2S is burnt with required quantity of air for producing a mixture of
H2S and SO2 in a combustion chamber. The feed acid gases are analysed for generating a
control signal for precise combustion of H 2S. The hot flue gases goes to Heat Recovery
Boilers and further to Catalytic Reactor 1 and 2 to produce elemental sulphur. The gas
from the second catalytic reactor goes to a catalytic bed adsorbent medium to adsorb the
non-reactant components and also reaction proceeds to produce more sulphur to drive the
reaction to completion. The catalyst is high efficiency, extra quantity of alumina catalyst.
The adsorbed sulphur is continuously stripped back and sent back to the Sulphur
Condensers. Post pit sulphur degassing is done to enhance recovery and reduce H 2S in
sulphur products. The unconverted H2S is burnt in a catalytic incinerator to remove all
traces of H2S and sent to stack via waste heat boiler for recovering the heat from the flue
gases.

12. Polypropylene Plant

The polypropylene plant process consists of the following basic steps:

1. Lymerisation
1. Random polymerization
2. Polymerisation & Impact polymer
3. Powder discharge and purging
4. Extrusion
5. Drying of pellets
6. Deodorization of pellets
7. Degassing
8. Bagging and Pelletisation

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Co-catalyst diluent solution is transferred to a reactor after proper conditioning. Mixing of

catalyst, co-catalyst and prepolymerisation of propylene occurs in the reactor. A portion of
propylene polymerises while the remaining acts as a diluent of the solid polymer.
Hydrogen is used as chain blocking agent. All the streams are conveyed to the reactor at
a constant flow rate in suitable ratios to achieve required properties of the product.
Polymerisation is performed in a loop tubular reactor. Reaction takes place at 30 –35
kg/cm2 pressure under temperature range of 50 -70 0C. Residual unreacted propylene is
continuously conveyed through scrubber in the recovery system.

Polymer powder collected at the bottom is conveyed to a bag filter kept at

atmospheric pressure to remove remaining unreacted monomer from the polymer. The
powder is discharged by gravity to a fluid bed where removal of residual monomer is
completed. Steam is injected to improve the product quality. The recovered monomer is
sent to compressors. Finally the polymer is discharged to a fluid bed dryer where final
drying is done by means of warm nitrogen circulating in closed loop. The dry powder is
transferred to storage silos.

13. Steam & Power Generation:

CPP produces and distributes power, steam and process boiler feed water for Jamnagar
Refinery Complex. All these products are distributed to the downstream units of refinery as
per process requirements. CPP consists of Gas Turbines and Steam Turbines for power
generation and heat recovery steam generators and auxiliary boilers for steam generation.
Design power generating capacity of CPP is 360 MW. It consists of 8 nos. of gas turbines
and 4 nos. of steam turbines. Design capacity of each machine is 30 MW. The present
complex power load is around 300 MW (Peak)
The installed steam generating capacity of CPP is 1500 TPH and is met by 8 nos. of
HRSGs and 4 nos. of Aux. Boilers. Each of these boilers is designed to generate 125 TPH
of steam at 115 kg/cm2 pressure and 510 Deg.C temperature. The total steam requirement
of the plant in normal running is around 950-1000 TPH.

Power distribution is done at 33 KV level throughout the refinery complex. 132KV

switchyard in CPP enables it to connect with GEB grid. Under normal operating conditions,
steam turbines and gas turbines operate in islanded mode. In case of power export or
import mode, RIL grid is synchronized with GEB grid. Power purchase (import) is done in
case of a total power failure and our internal sources of power are not available. Two
emergency Diesel generators (EDG) each having a design generating capacity of 3.2 MW,
supply emergency power to the entire complex (as identified) in case of a total power
failure. Internal power distribution in CPP is done at 6.6 KV and 415 V levels.
Boiler feed water is made available through 7 nos. of de-aerators in CPP. There are 3 de-
aerators for generating HHP boiler feed water and 3 de-aerators for process boiler feed
water. One is a common de-aerator, which can be lined up for either side as per
requirements. Normally common de-aerator is lined up towards CPP side. Process feed
water is distributed at HP, MP and LP pressure levels to the refinery. HHP boiler feed
water is consumed only in CPP.

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Process steam to refinery is supplied at three pressure levels, namely HP, MP & LP. There
are few other process steam generators in the refinery complex. All consumers and
producers of steam are connected to a common header at each level of pressure. HP and
MP steam from CPP are normally in the export mode and while LP steam can be in import
or export mode. All header pressures are monitored and maintained by CPP on
continuous basis. CPP consumes HHP steam in Steam Turbines, HP steam in drives, MP
steam in drives, Steam turbines and Aux. Boiler, LP steam in Aux. boiler air pre-heater and
LLP steam in de-aerators.
CPP gets raw materials from other units in refinery. DM water, Instrument air, Plant air,
Nitrogen, Cooling water for STG condenser, Utility water and potable water are supplied by
Utility plant. Dedicated air compressors at CPP end supply instrument air for CPP in
normal case. However CPP air system is connected to the refinery air system so as to
receive instrument air if required. Liquid fuels are supplied by RTF. Gaseous fuels like
RFG and Pilot Gas are supplied by Hydrogen plant for HRSG and Auxiliary Boilers. RFG
for Gas turbines is supplied by FCC plant directly. Fresh Cooling water and secure Cooling
water are supplied by aromatics plant from cooling tower # 3.
The effluent from boiler blowdowns is collected in a blowdown sump from where it is sent
to Aromatics cooling tower # 3 through return line of FCW, as makeup water. Oily water
sewage is sent to ETP for further processing through pipelines.

13. Utilities Plant:

Seawater desalination units (five streams) in combination with demineralization units

produce the required pure water for steam generation and other utility requirements. Utility
plant also supplies instrument and plant air to the process units through centrifugal air
compressors. Three nitrogen-manufacturing units cater to the gaseous nitrogen
requirement of the complex. Five cooling towers are provided for supplying cooling water
to the entire complex for removal of process heat in heat exchangers. An effluent
treatment plant (ETP) treats the effluent water from the units and the treated effluent is
recycled back to the cooling towers as make up water and also used for horticulture.

14. Tank farms & Marine facilities

Three Tank Farms-namely Refinery Tank farm (RTF), Rail Road Tank farm (RRTF) &
Marine Tank Farm (MTF) are provided to store raw materials, intermediate products and
final products. The tank farms consist of mainly floating roof storage tanks to store the
liquid fuels and spheres to store LPG & propylene.

Refinery Tank farm stores Raw material in the form of crude & fuel oil, intermediate feed to
the units and final products for transfer to MTF and RRTF.

RRTF receives and stores liquid fuel products from RTF for dispatch through rail wagons
and road tankers to oil companies and other customers.

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Reliance Industries Limited, Jamnagar

MTF receives and stores products from RTF for dispatch through ships to oil companies
and other customers. MTF also receives and stores raw materials such as crude through
ships for further transfer to RTF.

Marine facilities include four Jetties to load fuel and petrochemical products into ships. Two
offshore SPMs (single point mooring) are provided to receive crude oil from VLCC (very
large crude carriers) and pump to the storage tanks onshore.

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