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Cracker RTO Approach

November 2019Team: Wasique Khan, Velagala V Reddy, Viknesh Raja, Fareed Khan

Presented by :

Velagala V Reddy

DISCLAIMER

Any statement, opinion, prediction, comment, or observation made in this presentation/publication are those of thepresenter/author only and in no condition should be construed necessarily representing the policy and intent of RelianceIndustries Ltd. (RIL).

The information presented herein are of the presenter/author’s own and in no way RIL attracts any liability for anyinconsistency or irregularity in terms of the accuracy completeness, veracity, or truth of the content of thepresentation/publication. In addition, RIL shall not be liable for any copyright infringement and misrepresentation for thepresented content as the content is presumed in good faith to be a creation of presenter’s/author’s own mind.

The scope of this presentation/publication is strictly for knowledge sharing purposes and not necessarily to provide any

advice or recommendation to the audience/readers. Any endorsement, recommendation, suggestion, or advice made by thepresenter/author shall be in his personal capacity and not in professional capacity as an employee of RIL. Any person actingon such endorsement, recommendation, suggestion, or advice will himself/herself be responsible for any injury/damage.

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Content

Reliance Industries Limited – Overview

APC - RTOs at Reliance

Cracker RTO Scope

In - House Furnace Model

CKR RTO - Model Features

Benefits and Timeline

Forward Path

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Introduction & Financials

Introduction & Financials

© Reliance Industries Ltd., 2019

Reliance IndustriesMarket cap of ~$ 125 billion

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India’s Most Profitable Company Today

Introduction & Financials

Energy Value Chain Consumer-centric Businesses

Refining and Marketing

◼ Largest, most complex single site refinery with 1.24

mb/d capacity

◼Consistently outperforming regional margins

◼ ~58% volumes placed in international markets

◼ Ranked Top 10 globally in key products

◼ 2nd largest producer of polyester fibre/yarn globally

◼ FY19 Production: 37.7 MMT

◼ Significant expertise in deep-water operations

◼ Substantial exposure in US Shale

◼ R-Cluster first gas expected in 2H FY2021

Petrochemicals

Exploration and Production

Reliance Retail

◼ India’s largest retailer by revenue ($18.9 bn)

◼ 10,415 stores with 22 MM sq.ft. space

◼ Presence across 6,600+ cities

◼One of the world’s fastest store expansion – added

~10 stores a day in last 2 years

◼ All IP-data network with latest 4G LTE technology

◼ India’s largest wireless data subscriber base : 306.7

Mn with net adds of 120 Mn in FY19

◼ ~10.9 GB per user per month

◼Carrying 71% of the total industry’s 4G data traffic

(CY18)

Reliance Jio

• Most profitable company for the year 2018-19. Recorded a net income of US$ 5.7 billion

• Revenue of US$ 90.1 billion, PBDIT of US$ 13.4 billion. Market cap of ~$ 125 billion

A market leader across energy and materials value chain (E&P, R&M, Petchem) and in consumer businesses (Digital Services and Retail)

US$1 = INR 69.155© Reliance Industries Ltd., 2019

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Forty Years of Phenomenal Growth

1977-87

• Cracker and Polymers @

Hazira

• Fiber Intermediates @

Hazira

• Upstream – PMT

• GDR Issue

• 50/100 Years Yankee

Bond

• IPO

• Polyester @

Patalganga

• Jamnagar Integrated

refinery and petrochemical

complex

• KG-D6 discovery

• IPCL acquisition

• Foray into organized retail

• Recron Malaysia

• Fortune Global 500

1987-97 1997-2007 2007-12 2012-19

• Jamnagar refinery &

petrochemical complex – 2

• KG-D6 production

• US Shale gas JVs

• Partnership with BP

• BWA spectrum

• Launched biggest ever

hydrocarbon capex

program

• Innovative financing –

perpetual bond,

EXIM facilities

• Polyester expansion

commissioned (PFY, PET,

PTA and PX)

• Elastomers (PBR,SBR)

commissioned

• Ethane project, ROGC

commissioned

• Acquired spectrum in

800/1800 MHz band

• JIO crosses 300 mn

subscriber milestone

• CBM production

• Gasification under

stabilization

© Reliance Industries Ltd., 2019

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Reliance APC-RTOs at a glance

✓ Cracker

✓ Butadiene

✓ Aromatics

✓ MEG

✓ PTA

✓ VCM/PVC

✓ ACN

Refinery

✓ CDU/VDU

✓ FCC

✓ Reformer

✓ Alkylation

✓ Hydrocracker

✓ Hydrotreaters

✓ Coker

✓ CPP

✓ Sulphur/Amine

✓ Endpoints

✓ RVP/ Flash

✓ Conversion

✓ CP

✓ LLDPE

Petrochemical

Polymers

Inferential

APC/RTO Coverage

RTO

✓ CDU/VDU

✓ FCC/VGOHT

✓ Coker

✓ Cracker

✓ Aromatics

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Scheduling

ROMeo Optimization

CLP

APC

DCS

Planning

Cracker Control Hierarchy

Furnace Cold CGC & Quench Hot Hydrogenation FM_C2C3

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Cracker RTO Scope

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Feed Handling and Cold

Recovery Unit

Furnace & TLEs

Quench TowerDilution steam

generationCGC

Ethylene Fractionator

Acetylene hydrogenation

Deethanizer

Demethanizer and chilling Train

Propylene Splitter

MAPD Hydrogenation

Depropanizer

DebutanizerGas

fractionator

Cracker Block Diagram

Steam Network

CW Network

C2R C3R

MVC BlockCustomization & Hx-Linkers

In-house Cracker Reactor Model - Milano

Fortran code for 133 Reactions,13 free radicals and 19 molecules. Total 32 components

Approach towards tuning – 7 kinetic Categories

Fortran dll used in excel for initial tuning of reactors.

ROMeo provides two options either OE code in Milano or CE black box models

Geometry exposed to GUI, can input any coil configuration

Temperature Profile is estimated approximately along the tube length

Pressure Profile is calculated along the tube length.

R→R*

R*+R’→R+R’’

R*→R’+R’’

R→R’+R’’

R*→R’*

R*+R’→R=

R*+R’*→R’’

Chain Initiation Reaction

Hydrogen Abstraction Reaction

Radical Decomposition Reactions

Radical isomerisationreactions

Chain termination reactions

Purely molecular reactions

Radical Addition reactions to Unsaturated molecules

FurnaceYield

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In-house Cracker Reactor Model - Milano

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Ethane Cracking Propane Cracking

Cracker Reactor Model and Design Yield Comparison

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In-house Cracker Reactor Model - Milano

Online tuning parameters on the Furnace model to match plant yields

Feed Distribution to different zones and modes of Furnace operations done by Switching Macros

Customized fire Box model as Radiation section

17 Furnace zone is modeled with each zone as single reactor.

Multiple Hx-Linker for convection Section

Faster and robust execution

TMT, CPR and Run-length constraints are approximated by regressed equations.

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Pressure drop equations are tuned in data reconciliation at high volumetric flowrate zones

Valve output Constraints are also included using the simple gain module and Hydrogenation reactors are approximated using Conversion reactor

APC MVs as optimization variable & CVs as Constraints. APC calculated variables are included in the model through calculation blocks

Multiple Hx-Linkers are used for cold box modeling

C2R, C3R & CGC Compressors modeled using performance curves

Configured Close loop Steam, BFW and Refrigeration circuits

CKR Model Features

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Execution Logics

Ramper Logic for ETs - Smoother APC movement.

APC Limits

Plant values that are outside APC Limits are NOT pushed further during Optimization by

considering them as Relaxed bounds

Reports

Automated Shift and Daily Reports to Operations, CTS and RTO Engineers

Performance Index

Unified Performance Index to track RTO benefits and its run time

Equipment performance

Report also contains detailed Furnace yields, column efficiency, heat exchanger U and Compressor efficiency.

CKR Model Implementation Features

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3 months

Open loop testing& Close loop commissioning

7 months

SubflowsheetBuilding

3 months

Integrating Flowsheet

1 months

FDS sign off

Kick off meeting

Online:

• Furnace load distribution

• Furnace conversion• Dilution Steam Ratio

• Recovery vs Energy

• Hx and Compressors Monitoring

Offline:

• Shift wise Top five profit improvement opportunities review

• Offline case scenarios testing, DBN Testing, Plant Troubleshooting, Equipment performance monitoring

Benefits and Timeline

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Repeat the success story at two other crackers

Graphical interface with RTO Target Historian

Advisory systems from Delta vectors for fouling prediction

Advisory Parallel run with engineering limit offline to evaluate maximum achievable profit

Ramper logic improvement

Hard limits in RTO to bring critical CVs within limits

Evaluation of better approach – All APC constraints vs accurate constraints

Forward Path

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