refining india 2025
112
80
0 2 1 3 4 6 5 8 7 9
110
Before PPO trial During PPO trial
70
108
60
106
50
104
102
40
100
30
Before PPO trial
During PPO trial
pH
Chloride (mg/L)
Iron (mg/L)
20
Ammonium chloride sublimation temperature
Main fractionator top temperature
10
During PPO trial
Before PPO trial
0
Dry gas
LPG
CRN
LCO
Resid
Coke
Conversion
ature before and during the PPO trial are given in Figure 4 . Co-processing of PPO increased conver- sion, dry gas, LPG, and cracked naphtha, and reduced LCO, resid, and coke yield. Product yields obtained during the trial are given in Figure 5 . Impact on corrosion parameters Processing PPO is suspected to cause cor- rosion in the main fractionator top trays and overhead condensers due to high chlo- ride and sulphur content. However, cor- Figure 4 Main fractionator top temperature and respective ammonium sublimation tem- perature before and during PPO trial
Figure 6 Main fractionator boot water cor- rosion parameters before and during PPO trial
Figure 5 Product yields before and during PPO trial at Mumbai refinery FCC unit
resource-efficient and environmentally responsible economy.
rosion parameters, such as ammonium chloride sublimation temperature, over- head condenser boot water pH, chloride, and iron content, were within the desired limits due to the low chloride, sulphur, and nitrogen content of the PPO selected for processing in the FCC unit. The main frac- tionator boot water corrosion parameters, which are monitored before and during the PPO trial, are given in Figure 5 .
it was transformed into fuels and propyl- ene, which is present in the LPG frac- tion. If propylene is recovered from LPG fraction, it can be transformed back into plastics such polypropylene and poly- acrylonitrile. This process closes the plastic loop and enhances both circular- ity and sustainability. It not only reduces our dependence on virgin fossil resources but also helps mitigate plastic waste accumulation. By integrating PPO into refining opera- tions, industries can contribute to a more
Summary PPO processing in the FCC unit was com- pleted successfully, with no negative impact on FCC product yields. Furthermore, there were no major operational issues related to unit corrosion or gum formation during this process. Co-processing of plastic pyroly- sis oil increased conversion, dry gas, LPG and cracked naphtha, while reducing LCO, resid, and coke.
Achieving circularity PPO was processed in an FCC unit, where
Driving value maximisation with process digital twins and data analytics
Jesse Mallhi, Paras N Shah, Sathiyanarayanan A, NC Chakrabarti, Narendar Mitta, and Vikas Deshmukh Reliance Industries Limited
Reliance Jamnagar features two ultra-large refineries, a petcoke gasification complex, and a refinery off-gas cracker petrochem- ical complex. It is committed to quickly adopting the latest digital technologies. To enhance productivity at Jamnagar, a uni- fied digital platform is being developed that integrates all functional areas with the nec- essary interfaces ( Figure 1 ). This will sim- plify processes, automate tasks, eliminate digital breaks, and promote collaboration among multiple stakeholders. The digital modules, consisting of digi- tal twins, handheld devices, CCTVs, smart devices, and virtual assistants, will enhance safety, reliability, and productivity, leading to increased profitability. Process Digital Twin The term ‘process digital twin’ is widely used across all types of industries, but peo- ple from different fields have distinct inter- pretations of what digital twins mean. As Markus Meissner aptly puts it, “Sometimes good things come in pairs: The digital twin.” In the context of continuous process man- ufacturing facilities, such as refining and petrochemical complexes, a process digital twin is a digital replica of all the unit oper- ations within a process plant. This includes chemical reactions, separation processes, heat transfer, and more, all represented through models designed to mimic actual operations and performance.
Digitalisation: Quantum jump in productivity, reliability, safety
Close loop operation Auditable compliance
Paper based with digital blinds
Connected plant Task guidance
Complete, accurate, consistent & single data version Design data, operations, maintenance Predict & prescribe actions Improve plant reliability & availability Collaborate with experts Chatbot, voice chat Quick access to asset model Timely support & actions Supplement competency
Noti cations & actions Collaborative team with connected work ows Timely response Knowledge access
C
Digital twin
Hand held
Improve situational awareness through video analytics to enhance Safety & health Security Productivity
Virtual Assistant
CCTV
Track & trace
Smart Wearables
Support operations & maintenance
Find when needed
Remote monitoring & support Immersive learning Guided instructions Knowledge transfer Manage skills gaps
People, material, vehicles Geo-fencing Enhance safety Enhance productivity
Digital data Speed & e ciency
Operations
Technical
Maintenance
Safety
Business
Procurement
Secutrity
Logistics
Project
Figure 1 Unified digital platform
The process of digital twins uses first- principles, hybrid, and self-learning machine learning (ML) and artificial intelligence (AI) models to achieve desired business objec- tives, such as operational excellence, reli- ability, availability, and safety. To mimic the actual operations, multiple models must be built and deployed ( Figure 2 ): ○ Real-time process simulation model : At the heart of the process digital twin is a real-time process simulation model. They are based on first principles and hybrid
Process models – First principle / hybrid based
Physics, Chemistry, Engineering simulation
Model
Statistical, ML & AI to generate insights Data analytics models – Data driven
Data
Data
Virtual space Physical space
Integrate high-quality data and value-added information for e ective and timely decision Interactive dashboard – Visualisation
Figure 2 Key components of process digital twin¹
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