25. Key performance indicators, such as syngas yield, hydrogen production efficiency, fuel utilisation, specific energy consumption, and equipment reliability, have all shown measurable improvement. This achievement reflects the combined impact of digital adoption, disciplined operations, and sustained focus on
Syngas fuel to power & steam
Gas treating units (Un shift)
Nitrogen
Petcoke
Sulphur product
SRU
Oxygen
Air
Gasi er
ASU
Gas treating units (Shift)
H to re nery
H producer
Raw syngas
Syngas fuel to power & steam
Gas treating units (Un shift)
SRU
Nitrogen
Sulphur product
Gas treating units (Shift)
H to re nery
Gasi er
H producer
Air
ASU
Oxygen
Petcoke
Gas treating units (Shift)
SNG product
SNG
ASU = Air Separation Unit SNG = Substitute Natural Gas SRU = Sulphur Recovery Unit
Figure 1 Petcoke gasification complex (PCG)
supplies approximately 70% of total fuel demand, enabling efficient, cost-effective energy generation for refinery operations. In addition, it accounts for around 50% of the total hydrogen requirement, which is essential for various refining processes, such as hydrotreating, hydrocracking, and residue upgrading. Notably, the PCG complex provides 100% of the on-purpose hydrogen, ensuring a reliable, continuous, and high-purity hydrogen source tailored to process units with critical hydrogen needs. “ The PCG complex provides 100% of the on-purpose hydrogen, ensuring a reliable, continuous, and high-purity hydrogen source tailored to process units with critical hydrogen needs ” Over the past year, the complex has undergone a significant transformation through the deployment of an advanced digital operations platform. This platform integrates real-time monitoring, predictive analytics, automated diagnostics, and performance optimisation tools across gasification, syngas clean-up, and hydrogen production units. By leveraging these digital capabilities, the operating teams have been able to enhance plant reliability, refine operating strategies, minimise energy losses, and improve decision- making effectiveness. As a result of these data-driven improvements, the PCG complex achieved its best-ever performance in financial year 2024-
process optimisation. The manufacturing process channels at Jamnagar are fully automated to ensure safe, reliable, compliant, and competitive operations. Performance across every unit, site, and the entire complex is consolidated into a single platform, enabling real-time visibility and informed decision-making. Advanced processes that not only enhance monitoring and operational excellence but also proactively prevent safety and reliability events have been implemented. The following are a few use cases: Smart data analytics End-to-end monitoring of feed : Feed flux management is critical to enable consistency in operation and performance. Variation in individual components, caused by variation in crude, leads to huge variation in petcoke ash components and, in turn, to variation in ash fusion temperature, which is not desirable for a stable process operation. Processes, equipment, controllers, energy, and process losses: Any process variations can cause vibrations in the mechanical components of equipment, leading to failure and negative variance in steam generation due to inefficient heat integration. Combined, these factors contribute to higher process losses. More than 180 AI and machine learning (ML)-based analytics are deployed for predictive analysis and real-time alerts. Example: Metal content in petcoke slurry is monitored from crude feed. The analytics predict the metal content for future days,
Refining India
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