RIL’s Breakthrough Technologies Asit... · 2020. 12. 18. · RIL Hydrated Sorbent CO 2 Capture Process RIL Process is 70% Lower Capex and 40% Lower Opex than Conventional Amine

Waste to Value : RIL’s Breakthrough Technologies

Dr. Asit K Das

Refining R&D Centre, Reliance Industries Ltd.

15th Dec 2020© Reliance Industries Ltd., 2020

Gasification India -Waste to Energy 2020 Web Conference

DISCLAIMER

2© Reliance Industries Ltd., 2020

Any statement, opinion, prediction, comment, or observation made in this presentation/publication are

those of the presenter/author only and in no condition should be construed necessarily representing the policy

and intent of Reliance Industries Ltd. (RIL).

The information presented herein are of the presenter / author’s own and in no way RIL attracts any liability for

any inconsistency or irregularity in terms of the accuracy completeness, veracity, or truth of the content of the

presentation/publication. In addition, RIL shall not be liable for any copyright infringement and misrepresentation

for the presented 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 the presenter / author shall be in his personal capacity and not in professional

capacity as an employee of RIL. Any person acting on such endorsement, recommendation, suggestion, or advice

will himself/herself be responsible for any injury / damage.

Hyper-Growth of Consumer Businesses Along With a

Robust Oil-to-Chemicals (O2C) Platform

Consumer Businesses Have Rapidly Scaled up to a Market Leadership Position in the Last Five Years

3

FY10 FY15 FY20

Others

Retail

Digital

Oil &Gas

O2C

$5.6bn$6.1bn

$13.6bn

Energy and others

100%

Energy and others

98%

2% Consumer

Energy and others

65%

35% Consumer

+13% p.a

+111% p.a

+8% p.a

EBITDA Has Grown 2x in Last Five Years

# 1 integrated O2C player# 1 integrated O2C player

Emerging retail player

# 1 integrated O2C player

# 1 technology and consumer player

Note: Exchange rate 1 US$ = INR 75.527; EBITDA includes other income; segment split based on Segment EBITDA excluding other income© Reliance Industries Ltd., 2020

RIL’s Breakthru Technologies : Waste to Value

Technology Can Create Value Out of Waste, Convert Challenge Into Opportunity


• Catalytic Gasification & Integrated CO2 capture

• RCAT HTL – Catalytic Hydrothermal Liquefaction

• Waste Plastic to Virgin Plastic – Chemical Recycling

Energy – India Centric Innovation

5

Gasoline and Diesel quality improvement

Crude to chemicals

Direct Syngas to high value chemicals

Methanol + Ethanol economy

Hydrogen as fuel for Fuel cell HEB

Improving EII

Availability of other Energy Sources

High ash Indian coal – Lignite

Agro biomass (220 MMTPA =

70 MMTPA Syncrude)

Municipal solid waste (50 MMTPA)

Waste plastics (5 MMTPA)

Food / other organic waste

High quality Bio-crude

Methanol/chemicals

Bio-ethanol

Bio-CNG

Biomass gasification to H2

Pipe gas availability

High efficiency solar panels

Low cost CO2 capture technology

CO2 to high value chemicals, bulk chemicals

Conversion of waste plastic to oil and

chemicals

Refinery and Petchem waste to high value

products

Algae to oil & chemicals

Renewables (Solar, Wind)

Availability

Affordability

Sustainability

Productivity

© Reliance Industries Ltd., 2020

6

Agri Biomass, High Ash Indian Coal :

RIL’s Catalytic Gasification

+

Integrated CO2 Capture


Catalytic Gasification of Indian Coal / Biomass – Green H2

Demo Plant planned; NITI Aayog shown keen interest – Ideal for India

7

Technology Merits

Novel hybrid green process with 3 patent filings

No need of ASU / pure O2 (air can be used) t and low temperature

catalytic process (< 750 deg C)

High reliability (on-stream factor:~3yrs vs. conventional:

3months), novel catalyst for production of high quality syngas

(H2 / CO) >3 vs. thermal < 0.7

Tested coal / petcoke / biomass and obtained >95% conversion

for petcoke and sub-bit’mns Coal / Lignite / Biomass without any

tar generation

Expected Benefits

40-50% lower CapEx & OpEx vs. Conventional Thermal Process

Ideal for high ash coals, agri-residue & petcoke in to H2, Syn

gas, methanol and ethanol @50% less cost

H2SSOx

Gasifier

Steam

`

Ch

ar

(>20 µ

m)

Syngas Recycle

20 µm(Mostly

Catalyst

Fines)

>800 ℃

Flue Gas

Cooler

NO

X R

emov

al

Particulate

Removal

BFW

Steam

SO

X

Scr

ub

ber

Sta

ck

CO2

Capture

Pure

CO2

Particles < 20 µm

(Mostly Flyash)

Particles < 20 µm

(Catalyst and Fines)

Particles < 5 µm

(Mostly Flyash)

Flue Gas

Fresh

Feed

CombustorBottom Ash

(< 40 µm)

Catalyst

particles

(~90 µm)

Air

Lift

Air

~25%

Car

bon

Con

vers

ion

~75%

Car

bon

Con

vers

ion

H2S

Scr

ub

ber

Formation of Tar in

case

of Thermal

Zero Tar in

Catalytic case

Condensed steam (excess & un-reacted) samples of biomass gasification


RIL Hydrated Sorbent CO2 Capture Process

RIL Process is 70% Lower Capex and 40% Lower Opex than Conventional Amine Route

8

Objective:

Development of hydrated sorbent process to

capture CO2 from refinery flue gases with min.

capex and energy consumption.

Technology Description & Advantages:

Adsorption based technology using a novel

highly stable solid sorbent in circulating fluid

bed reactor.

Completed pilot scale studies in circulating dual

fluidized bed system and Achieved single pass

>90% CO2 removal efficiency.

Filed 5 patents, completed design package and

established linkage with CO2 Utilization

technologies.


Gasification Economics : Catalytic vs Thermal

Catalytic Gasification Economics much better = Syn Gas @ Shale Gas price

100 MT/yr high ash Indian Coal = 25 MTPA BS VI Diesel , 10% of refining

250 MT/yr Biomass = 60 MT/yr of Syncrude or Green MeOH or Green H2 equivalent


Feed Type High Ash Coal (40%) Agro-Biomass

Process Thermal Catalytic Thermal Catalytic

Temperature / Pressure ℃ / bar 1500/45 ≤ 800/≤ 4 1400/45 ≤ 700/≤ 4

Feed rate (1 MMTPA) TPH 122.2 122.2 122.2 122.2

Total Product Syngas TPH 169.8 171 153.4 163

H2/CO mole ratio 0.63 >3 0.63 >4

Syngas Calorific Value Kcal/kg 2917 3671 2870 3630

Cold Gas Efficiency %

10

MSW, Food Waste, Organic Sludge, Wet biomass :

RIL’s Catalytic HTL Technology


RCAT-HTL for Bio-crude & Biofuels : Waste to Wealth

Green Solution to World’s Growing Energy Demand Using Waste as a Resource11© Reliance Industries Ltd., 2020

Replaces fossil crude and

produces climate friendly

transportation fuels

Handles any Organic Waste

Feed Flexible Technology

(Agro waste, MSW organics, food waste, food

processing waste, manure, bio-solids, ETP

sludge, industrial waste, mixed non-recyclable

plastics, automobile waste tyres)

Energy Efficient :

Uses water in waste as a reactant and

recovers fertilizer-rich water. No need of drying

wet waste

Drop-in Renewable Crude as Product :

Energy-dense liquid crude, compatible with

petroleum crude. Can be processed in existing

refining infrastructure. No change required in

engine technology

RCAT-HTL Waste Collection and Processing Existing Refinery Infrastructure

Green

Drop-in Crude

Diesel MFOJet

70 MMTPA Bio-waste in

India= 20 MMTPA Biocrude

Biomass to Energy- Technology Comparison

Converting Biomass to Energy-Dense Liquid Hydrocarbons is More Efficient12© Reliance Industries Ltd., 2020

Dry Biomass to Electricity

1 KG = 1.7 kWh

= 1465 KCAL

Thermal eff = 27%

Dry Biomass to HC Fuel

1 KG = 280 GRAM

= 2960 KCAL

Thermal eff = 56%

Dry Biomass to Ethanol

1 KG = 252 GRAM

= 1780 KCAL

Thermal eff = 34%

*Wet Biomass to Biocrude 1

KG = 500 GRAM

= 3475 KCAL

Thermal eff = 66%

Biogas

= 2890 KCAL ,

Overall Thermal eff = 48%

Biogas to Electricity

= 1.25 kWh

Overall Thermal eff = 18%

Any Organic Waste

agri-residues, bagasse, lignin,

food, dairy waste, etc.

ETP Sludge Dairy waste

Food Waste Agri residue

RCAT- HTL RCAT-HTL Biocrude

Catalytic Pyrolysis Gasoline/Diesel/Kerosene

Fermentation Ethanol

Anaerobic Digestion

Power

Biogas

Biogas

Power Generation Power

RCAT HTL - Assessment with Competing Technologies

RCAT-HTL Scores Higher Among All Technologies 13© Reliance Industries Ltd., 2020

Biomass Conversion Options


Basis : 165,000 T / Yr (500 TPD dry) Paddy Straw as feed:

Bio-gas2G Bio-

Ethanol*

3G BioethanolCat Gasification+ Gas

Fermentation

RCAT-HTL

Feed Wet Wet Dry Wet / MSW

ProductsBiogas, 79%

Residue

EtOH, Gas,

60% ResidueEtOH, no residue.,CO2

Bio-crude (1650

bbl/d), 75% C conv

Main product (in kg) / MT of feed 133 160-198 448 500

Capex, M$ 0.4B B 1.6B .8B

Net Profit, M$ / year C C-10 C+26 C+16

* Prelim Techno economic evaluation of 2G Ethanol with co-products from Rice straw -+ P. Ranglanathan, Biomass Conversion and Bio-refinery 2020

15

Waste Plastic to Virgin Plastic

: Circular Economy


Why Current Technologies are so Problematic?

A Superior Continuous Catalytic Process is Desired to Address All Issues16© Reliance Industries Ltd., 2020

Segregation

of Feed

Highly viscous &

hot slurry

pumping (no

solids allowed)

Issues with

processing of

as-received

waste plastic

Sticky Char & Tar

formation, lowers

the heat transfer

with time,

agglomeration, ‘HC’

leakages to

surroundings

high vapor ‘RT’,

excess thermal

cracking, mostly

non-catalytic,

product vapor-char

separation

Lower Liquid yield

High Coke & residue

Liquid quality: Poor

(Low Gasoline

fraction with less

stability & low RON)

Diesel fraction: high

freezing point & low

Cetane value

Liquid quality

upgradation reqd.

Pre-Processing Issues Operational Issues Product Quality Issues

Catalytic Pyrolysis Reactor

Waste Plastic +Catalyst

Char + Spent Catalyst

Water

Water

Coolant

Coolant

Regenerator

Gas

CharacteristicsConventional

(Thermal)

RIL

(Catalytic)

Product yields

Gas (C1-C5 )% A ~ A - 5

Liquid (C6+) % A ~ A + 9

Char + Loss A ~ A - 4

Liquid Distribution

Gasoline % A ~ A + 37

LCO A ~ A - 20

CSO A ~ A - 10

Process Conditions

Temp, oC A ~ A – 60

Catalyst

recycle

Process Novelty

Capable to process as received

Feedstock, MLP, SUP, EoLetc.

Novel design reduces vapor

residence time and increase liquid

yield

Proprietary Catalyst: Low Cat/Feed,

Re-generable & low cost

Liquid stable & less acidic compared

to thermal products, 35 API low S

Syn crude

Pressure management inside

reactor to prevent HC vapor

leakages

Low temperature minimizing energy

requirement

No chocking, scaling,

agglomeration: enhances reactor

cycle length

RIL’s Novel Continuous Catalytic Pyrolysis

Best in Class Process for Waste Plastics Conversion with High Liquid Yield

Continuous Pilot Scale Studies Over; Demo Scale Planned12© Reliance Industries Ltd., 2020

Diverse Feedstock Tested


Robust Technology for Unsegregated and Uncleaned Feed

High Quality Liquid Product


Liquid Product as Petrochemical Feedstock in MCC or High Quality Transportation Fuel

Products obtained from the catalytic pyrolysis of waste plastics @ Thermal Temp - 65℃

Liquid obtained from catalytic & thermal pyrolysis of diverse waste plastics Thermal pyrolysisLiquids

major components

Wax

Oligomers

Tri/Di olefins

Alkanes

Catalytic pyrolysis

Liquids

major components

Aromatics

Mono Olefins

Iso-paraffins

Naphthenes

Multi-Zone Catalytic Cracking (MCC) –

Direct Crude & Distress Streams to Olefins + BTX

Waste Plastic to Oil as MCC Feed : 55% Circularity to Virgin Plastic

20

Regenerator

C4

Recycle C4

C 5-C 6 Naphtha

Separation

Section

DG

C2

C3

LC

O

CSO

LCN, HCN

Reactor

TI

LT

Methanol

Refinery with Conventional

Cracking

CDU+VDU+FCC+DC

Crude

Fuels

RIL Multi-zone Catalytic

Cracking

MCC

Crude

Fuels

Feedstock for Petchem(>70% yield)

Feedstock for Petchem (~10-15% yield)

MCC yields C2 ≥ 24% , C3 ≥ 33% BTX ≥ 14%

MCC= High Severity FCC + Steam cracking + Methanol to Olefins (MTO)


THANK YOU29


Documents

RIL’s Breakthrough Technologies Asit... · 2020. 12. 18. · RIL Hydrated Sorbent CO 2 Capture Process RIL Process is 70% Lower Capex and 40% Lower Opex than Conventional Amine