national award for excellence in energy management...

Barauni Refinery-in harmony with nature 1

Barauni Refinery

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National Award ForExcellence in Energy Management 2017

PRESENTATION BY

BARAUNI REFINERYINDIAN OIL CORPORATION LIMITED

30,31 August & 1 Sept 2017

Hyderabad International Convention Centre


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Company Profile.

Barauni Refinery Block Flow Diagram

Energy & Loss Performance.

SEC trend in last three (03) years

Global Benchmarking

ENCON projects in last three (03) years

Energy Monitoring format at Barauni Refinery

Utilization of Renewable energy.

Utilization of waste as fuel.

GHG emission

Innovative Projects

Certificates

PRESENTATION AGENDA


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Company Profile


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Indian Oil Corporation -

The Future of Indian Energy

Strong Focus on Innovation Through R&Dand Alternate Energy Sources

Integrated Operations Across the entireEnergy Value Chain

Pan-India Pipeline Infrastructure

Leading Market Share Across Portfolio

Largest Refiner in the Country

Driven by a Management TeamThat has Delivered Results

● 11 refineries with 80.7 MMTPA Capacity

● Nearly 35 % of National Refining capacity

● ~50 % petroleum market share with over45212 touch points

● 13,000+ km pipelines for crude oil, productsand natural gas with a total capacity of 93.7MMTPA & 9.5 MMSCMD respectively

● 2nd largest domestic player in Petrochemicals

● Overall 454 patents and growing

● New focus on Alternate and RenewableEnergy (Wind, Solar, Biofuels, Nuclear)

● Consistent growth and profitability

Strong Support from the Government ofIndia

● Government nominated Directors on IOC Board

● 11 Refineries out of 23 Indian Refineries

Note: Company Filings and Petroleum Planning and Analysis Cell (http://ppac.org.in/).3USD-INR:62.5050 (as on March 31, 2015)

http://ppac.org.in/)













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Units at Barauni Refinery

UNITSCAPACITY (MMTPA)

Year of Commissioning

Licenser

Primary UnitsAVU-I 1.75 1964 RussianAVU-II 1.75 1966 RussianAVU-III 2.5 1969 In-houseSecondary Processing UnitsCOKER-A 0.6 1964 RussianCOKER-B 0.5 1986 EILRFCCU 1.4 2002 SWECHGU-1 0.034 2002 Haldor TopsoeHGU-2 0.02 2010 LindeSRU 2 X 40 MT/day 2002 StorkBiturox 0.15 2016 PörnerCatalytic Reforming Unit 0.3 1997 IFPDHDT 2.9 2002 UOPMS Quality Upgradation UnitNHDT 0.183 2010 AxensISOM 0.126 2010 AxensSHU 0.322 2010 AxensHDS 0.225 2010 AxensRSU 0.274 2010 Axens


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EQUIPMENTS CAPACITY

BOILERS

B-1/2/3/4,MT/HR 75

B-5, MT/HR 75

B-6, MT/HR 150

TURBINES

STG-1/2 , STG-3 ,STG-4MW 2X12, 12.5, 20

GAS TURBINEs,MW 2 x 20

HRSGs, MT/HR 2x48

DM PLANTS

DM PLANTS ,M3/HR 3 x 140

DM PLANT (BXP) , M3/HR 2X130

COOLING TOWER

BXP COOLING TOWER,M3/HR 16260

PROCESS COOLING TOWER,M3/HR 13500

CRU COOLING TOWER, M3/HR 1200

TPS COOLING TOWER, M3/HR 6000

POWER & STEAM GENERATION FACILITIES


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CRUDE

FUEL GAS

LPG

CRU MS

SRN

SKO

H2

PLANT

DHDT

COKER

A/B

RFCCU

HSD

LRU

LSHS

RPC

ARU/SRU SULPHUR

LPG MEROX

GASOLINE MEROX

FLOW

DIAGRAM

LDO

CBFS

AVU-IAVU-II

AVU-III

MSQ

New H2 Unit

BITUROX BITUMEN

Block Flow Diagram


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Projects coming up in Barauni refinery

1. Process units for BS-IV compliance: PRIME G revamp, DHDT revamp from 2.9 MMTPA to 3.3 MMTPA, NSU revamp, New Prime G, New NSU, New CCR.

2. Indjet project: New ATF unit using IOCL R & D technology - First of its kind. 220 KTA

3. BR 9 project: New AVU, New NHDT (ISOM), RFCCU(Revamp), New DHDT, New OHCU, Coker B (Revamp), New HGU, New SRU)

57 67.2144

1327New FGC

RO Plant

IndJet

BS-IV/V projects

All figs in ` Cr.

4. In addition to above, Barauni expansion Project to 9 MMTPA at a cost of Rs. 8287 Cr. Has been approved.


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Energy and Loss PerformanceSEC trend in last three (03) years

Global Benchmarking


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60005944

65456526

1945

1500

2500

3500

4500

5500

6500

7500

8500

9500

2014-15 2015-16 2016-17 2017-18

CR

UD

E T

’PU

T (T

MT)

YEAR

Design

Actual

APR’17 TO

JULY’17

M&I Shut down for AVU III

CRUDE T’PUT

Highest Ever

Th’put

Capacity Utilization: ~ 108% of design


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84.4

81.7 80.5

76.95

60

65

70

75

80

85

90

2014-15 2015-16 2016-17 2017-18

MB

TU/B

bl/

NG

RF

Year

ACTUAL3.1 %

1.47%

4.4%

APR’17

TO

JULY’17

SPECIFIC ENERGY CONSUMPTION [MBN]

Rate of reduction: ~ 3% per annum

Barauni Refinery is under PAT II and 2018-19 target for MBN : 78.3


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113.4 112.5

86.4 85.6

40

50

60

70

80

90

100

110

120

2014 2016

Ene

rgy

Inte

nsi

ty In

dex

EII

Year

Solomon Global Benchmarking

Barauni refinery average

Asia pacific average

0.8 %

Solomon Global Benchmarking – Comparison of Energy Intensity Index


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ENCON projects in last three (03) years


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ENCON Schemescompleted in 2014-15


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ENCON- Schemes: 2014-15

S No. ENCON SCHEMESSRFT/Year

Completed on

Investment(Rs. Million)

/ Payback

1 DHDT Stabilizer Off gas (lower H2 content) routed to RFCCU WGC instead of DOG PSA

1320 Apr’14 -

2 CRU O/G directly routing to DHDT Make up gas header by-passing K-5 Compressor

240 Apr’14 -

3 Coker-A Furnace pass flow reduction 375 Apr’14 -

4 Introduction of Dead Band Facility in feed surge drum / Reflux drum to avoid intermittent flaring.

250 May’14 -

5 Make up water heater (MUWH) in HRSG-II. 1800 June’1438.3

7.5 Month

6 Reduction in Gas / Oil ratio in NHDT (MSQ)to reduced RGC load from 50% to 25%

550 July’14 Nil

7 Retrieval of intermediate gland and rear gland steam of TG-1

620 July’14 -


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Completed on


/ Payback

8 Coker-A Single Furnace Operation 4100 Aug’141.8

0.15 Month

9 Installation of Auto water drain system in Product tank draining.

360 Aug’140.8

0.78 Month10 Lower Gas/Oil ratio & Ascending WABT

profile in DHDT with Anti-surge Opening5400 Nov’14 -

11Glass APH in AVU-I/II. 310 Nov’14

8.59.7 month

12Telescopic Insulation in Reformer tubes. 150 Nov’14

0.71.6 month


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Completed on

Investment(Rs. Million /Payback

13

Step-down of steam pressure for heating in feed heaters / re-boilers/ stripping steam • Use of LP steam for stripping in place

of MP steam. (AVU-III) • MP steam in RFCC naphtha splitter

reboiler instead of HP steam

3000 June’14

Nov’14

-

14 Step-less capacity control system in second MUG compressor (702-K-02 B) of DHDT.

860 Feb’15

Total 19335


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Completed on


/ Payback

1Installation of Kettle type heat exchanger from DHDT R/D

3200 Mar-1552.1

5.7 Month

2 Routing of RSU off gas to RFCC WGC 2000 Jul-15 -

3 Routing of DHDT Stripper off gas to LRU section 300 Jul-1522.2

46 Month

4Condensate recovery from Boiler-6 steam coil APH (SCAPH)

160 Jul-15 -

5 Recovery of Boiler-6 CBD Flash steam 120 Aug-15-

6Routing of MP steam from DHDT Kettle HE to RFCCU GSU Re-boiler

240 Aug-15-


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Completed on


/ Payback

7Provision of routing of vapor heating condensate of coke chamber back to quench column

250 Aug-15 -

8 RSU column completely bypassed 1580 Aug-15-

9 Stoppage of steam in redundant IFO tanks in TPS 200 Aug-15-

10 Steam Trap System Management 300 Sep-15

11Replacing HP steam in SHU, NHDT, ISOM & SHU preheater with MP Steam

300 Dec-15 -

12Load reduction of one air compressor by segregating compressed header for RFCC & Coker

55 Dec-1557.1


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Completed on


/ Payback

13

Optimization through column pressure reduction, stoppage of air fin coolers in units and cooling towers, stoppage of cooling water pumps, stripper steam optimization in CDU/VDU in winter

1200 Feb'16 -

14Replacement of normal tube lights with LED's

150 Nov’150.4

4.77Month

15Steam leak rectification through external agency

250 Jan’16 -

TOTAL 10305


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Completed on


/ Payback

1Rectification of faulty damper in AVU-II Crude Heater.

1500 Oct-16 -

2Low recycle ratio operation in Coker after revamp.

2000 Jan-17643

113Month

3 Steam traps system Management. 590 Oct-16 -

4DHDT servo valve repair and optimization in condensing mode

1000 Jan-17 -

5 DHDT stripper pressure reduction 120 Aug-16 -

6 SWS stripper pressure reduction 100 Sep-16 -

7Installation of oil catch pit in AVU I/II to recover Desalter oil carry over

50 Feb-17 -


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Completed on


/ Payback

8 DIH pressure reduction 300 Jul-16 -

9Compressed air interconnection scheme with N2 unit

400 Oct-16 -

10Segregation of facilities for processing slop in AVU I/II/III and Coker

- Jun-16 -

11Commissioning of scheme for routing of off-spec during AVU start up to crude tank

100 Jul-16 -

12Scheme for LP steam header connection between Units & TPS

600 Apr-1616.2

16.8Month

13Segregated high pressure dedicated service air line installed for the critical service

200 Apr-165.7

17 Month


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Completed on


/ Payback

14 Solarization of non plant building 280 Mar-1768.9

146 Month

15 Use of LED lights 50 Feb-170.4

4.7 Month

Total 7290


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ENCON SchemesCompleted / Planned

in 2017-18


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S No. ENCON SCHEMESSRFT

/Year Status

1 Installation of high efficient packing internals in RFCC stripper

800 Completed in Aug-17

2 Replacement of CAPH modules in AVU-I/II 300 Completed in Aug-17

3Compressed air & N2 leak survey through external agency 250 Completed in Jun-17

4MFM in LPG transfer line to/from Bottling Plant 100 Completed in Jun-17

5Closed draining of HSD tanks in CBD instead of OWS 200 Target Completion: Dec-17

6 Installation of Coalescer in GT Naphtha line 50 Target Completion: Oct-17

7Desalter study by the external agency (Slopreduction)

100 1st phase completed. Target: Dec-17

Total 1800


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Long Term ENCON- Schemes & Future Target

S No. ENCON SCHEMES SRFT/Year Completion

by

1 Utilization of Organic Rankine cycle for low level heat recovery from DHDT run down

3000 Dec-19

2 Green cooling tower in the new projects 100 2018

3 Processing of RLNG in HGU-I and GT’s at BR 3600 Mar-20

4 Installation of supplementary firing GTs 2700 Mar-19

5 Installation of Plate type HX in ARU & SWS 1500 Mar-19

MBN Outlook for 2017-18 : 75.5MBN Outlook for 2018-19 : 75.0PAT Target for 2018-19 : 78.3


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• Energy Monitoring format at BarauniRefinery

• Utilization of Renewable Energy

• Utilization of Waste as fuel

• GHG emission


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Energy Per Unit T’put

MBN

St./Fuel ratio

kWh/Fuel ratio

Comp. with Best / design Val.

Tar. Act.

Gap Analysis

Implementation

Action plan Identfn.

Energy Monitoring at Barauni Refinery

Setting Target

Brain Storming


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Energy Monitoring at Barauni Refinery

S. No.

Energy Parameter FrequencyDesign

/Benchmarking

ActualAction plan

1 Preheat of units Daily

2 Stack temperature Daily

3 Flare monitoring Daily

4GT/STG/TPS/Process Heater efficiency Daily

5 Steam Power balance Daily

6 Compressors Spill back opening Daily

7 Fuel & loss Balance Daily

8Specific Energy Consumptionmonitoring (Unit wise)

Daily

9 Hydrogen Balance Daily

10 Slop Oil monitoring Daily

11 Hot feed maxisation Daily


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Best Practices followed at Barauni Refinery

S. No. Best Practices Frequency

1 Generation of Daily ENCON report Daily2 Furnace / Boiler survey Weekly

3 Steam leak survey/ trap management Fortnightly

4 PSV passing survey Monthly

5 Loss control survey Monthly

6 Insulation survey Quarterly

7 Compressed air / N2 leak survey Quarterly

8Compressor/Motors/Pumps/Blowerperformance survey

Monthly


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Best Practices followed at Barauni Refinery

S. No. Best Practices Frequency

9 Ejector performance check Quarterly

10

Setting monthly targets based on previousperformances/ theoretical , monitoring &Review by Management for ENCON parametersvis a vis targets

Weekly / Monthly

11Monitoring of product Run Downtemperatures

Monthly

12 Suggestion Schemes for all employees Continuous

13 Encon suggestion week Annually

14 Energy Conservation awareness programmes Annually

15Management Review Encon parameters vis-a-vis Monthly targets

Monthly


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Utilization of Renewable Energy Sources (SOLAR PANEL)

Year New Installation Annual Energy Generated

2015-16 25 KW 23.2 MW

2016-17 1 MW 856.1 MW

2017-181 MW

(Under installation)


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Fresh Water Consumption

901802

714 757905

822722 683 662 632

1.553

1.182 1.011 1.069

1.387 1.138

0.976

1.007

0.889 0.849

2004-05 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 (till Feb'17)

FW consumption (m3/hr) Fresh Water Consumption / MT of Crude (m3/MT)

22.5% reduction in

5 years

Additional water demand

for MSQ facilities-2011-12

Commissioning of Modernized

ETP- 2014-15

16 % reduction in

3 years


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Fresh water consumption. Fresh water consumption reduced by 4.5 % in2016-17 over last year through various water conservation schemes.

Rain Water Harvesting: 14 nos. of Rain water harvesting projects have beenimplemented in refinery and township since 2011.

Effluent Quality Improvement : MINAS standard as given by MOE&F iscomplied through ETP / BTP modernization project.

Water Efficient Process: 100 % reuse of treated effluent water inside refinery. Green House Gas Emission, (GHG):

•For 2016-17 : 0.24 MTCO2e/MT crude .

Renewable Energy generation: Solar panel in building / solar street lights /Solar water heater have been installed in Refinery and Township.

Carbon Neutral events: 6003 no. of Trees planted in both refinery andtownship for reduction in GHG during 2016-17.

Green House Gas Emission, (GHG):


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2800 2840.3 3014.1

60

560

1060

1560

2060

2560

3060

3560

2014-15 2015-16 2016-17

MT

PER

AN

NU

M

Year

Flare Gas Recovered

Waste fuel Utilization …

Rate of Increase: ~ 3.5 % per annum

Utilization of Waste as fuel Sources

1. Oil recovery from ETP and Slop processing2. Oil recovery from Tank Sludge during M&I


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14.3

14.6

15.7

12.5

13.0

13.5

14.0

14.5

15.0

15.5

16.0

2014-15 2015-16 2016-17

Co

mp

aris

on

of

CO

2 E

(MT)

CO2 Emission (* 10^5 MT)

GHG Emission at Barauni Refinery CO2 E(MT)

Increase due to increase in processing of Crude


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118115

94 94

50

60

70

80

90

100

110

120

130

2014 2016

Car

bo

n E

mis

sio

n In

dex

Year

Barauni refinery average

Asia pacific average

Global Benchmarking -Carbon Emission Index

Reduction by ~2.5%


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Implementation of Green Supply Chain

1. Complete change over from BS-III norms to BS-IV since Jan’17 :

Investment worth Rs 1327 Crores

2. Preparedness for change over to BS-VI from 2020

3. Selection of Catalyst and Technologies for improving yield of LPG

inline with PMO Ujjwala Yojna

4. Replacement of IFO with Natural Gas planned in GT’s and Furnaces


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INNOVATIVE PROJECT 1Coker-A Single Furnace

Operation


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SIMPLIFIED PROCESS FLOW DIAGRAM OF DCU


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RECYCLE RATIO:

Recycle ratio is the ratio of secondary feed ( furnace feed flow) to primary

feed (fresh feed to column)

Recycle ratio = secondary feed / primary feed

EFFECT OF RECYCLE RATIO:

Increase in recycle ratio results in high coke yield and low distillate yield,

hence low recycle ratio is favoured for high distillate yield and low coke

yield.

Coker-A Single Furnace Operation


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WHY-WHY ANALYSIS

PROBLEM 1:

LOW DISTILLATE

YEILD

HIGH RECYCLE OPERATION

Why ?

TWO FURNACE OPERATION WITH HIGH SECONDARY FEED

Why ?

PROBLEM-2:

HIGH COKE

YIELD

PROBLEM-3: HIGH

FUEL AND POWER

CONSUMPTION

BOTH COLUMN

BOTTOM PUMPS AND

FD FANS IN LINE

CONTINOUSLY


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Before Transfer line modification :• Before modification both the furnaces F-01A/B & both the column bottom pumps

P-6A/B were continuously in line for two block operation

• In previous years Recycle Ratio was optimized by decreasing furnace Pass flowfrom 41m3/hr to 33m3/hr in stepwise manner. Further pass flow reductionwas limited to furnace cold oil velocity limitation (1.5m/s).

After Transfer line modification:

• Now only one furnace F-01A & one column bottom pump is in line with bothblock operation.

• Low recycle ratio of 1.3 is achieved with decrease in secondary feed to furnacewith one furnace operation .

• Only one column bottom pump & one FD fan in line while the other is kept instand by. Hence, reliability improved.

FURNACE TRANSFER LINE MODIFICATION


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BEFORE

CO

LU

MN

-001 FURNACE-01A FURNACE-01B

R

P-6A

P-6B

R-1/R-2 R-3/R-4

FRESHFEED



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AFTER

CO

LU

MN

-001 FURNACE-01A FURNACE-01B

R

P-6A

P-6B(STAND BY)

R-1/R-2 R-3/R-4

BLIND

BLINDFRESH

FEED

BLIND



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YIELD PATTERN

UNIT BEFORE AFTER

GAS % 12 8.0

LPG % 3.5 2.0

NAPTHA % 7.5 7.1

KERO % 13.0 17.4

GAS OIL % 18.5 20.0

FUEL OIL % 1.5 3.5

RFO % 14.0 16.0

COKE % 30 26.0

TOTAL % 100 100

COMPARISION OF YIELD PATTERN:


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37 38 3941

45

0

5

10

15

20

25

30

35

40

45

50

Apr'14 Jul'14 Oct'14 Jan'15 Apr'15

Distillate Yield (in %)

IMPROVEMENT IN DISTILLATE YIELD AFTER MODIFICATION


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BENEFITS ACHIEVED

ATTRIBUTES

PRODUCT YIELD

IMPROVEMENT

REDUCTION IN FUEL

& POWER

CONSUMPTION

IMPROVEMENT IN

RELIABILITY

IMPROVEMENT IN

SRF(%)


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Modifications / Benefits:

Coker-A Transfer line modifications done & Single furnace operation implemented.

Recycle Ratio reduced from 1.7 to 1.2. Drum pressure reduction from 2.9 to 2.5 kg/cm2g.

Only one MF bottom pump operation.

Direct fuel saving ~ 5-6 MMKCal/hr (Saving of : 4100 SRFT/yr )

#1 (R) BRA.3FT 1303.PV 11/13/2014 21:48:00 805.29 M3/HR (Raw) FG FLOW T O COKER_A FURNACE

#2 (R) BRA.3FT 1403.PV 11/13/2014 21:48:01 669.64 (Raw) FG FLOW T O COKER_B FURNACE**

0

500

1000

1500

2000 10/3/2014 02:10:04 1/31/2015 02:10:04

COKER-A FG CONSUMPTION @ 120d0h0m0s

FG Consumption

in F-01A/F-01B

2400-2600 kg/hr

FG Consumption

in F-01A

1700-1900 kg/hr

Furnace F-01B S/D

Transfer line

Modifications


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INNOVATIVE PROJECT 2Installation of Kettle Type Heat

Exchanger in DHDT


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BEFORE

Pump

Stripper

To product coalescer

Air fin cooler

702-E-12

702-E-01

E-4

Run Down Ex Air Cooler

195°C

Temperature

outlet of Stripper

is 235 degree C

Diesel R/D Stream

Installation of Kettle Type Heat Exchanger in DHDT


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AFTER

Pump

Stripper

To product coalescer

Air fin cooler

702-E-12

702-E-01

E-4

E-1

BFW

Saturated M.P.

steam generation

at 6 t/hr

BFWDiesel R/D

Sat. M.P.

Run Down

Ex Air

Cooler

160°C



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#1 (R) BRA.702FI5202.PV 7/17/2015 07:47:02 11137.64 DEGC (Raw) MP ST EAM GENERAT ION EX E-25**0

3750

7500

11250

15000 7/7/2015 16:41:16 8/21/2015 16:41:16

New Plot Title @ 45d0h0m0s


Kettle Heat Exchanger installed in DHDT to recover heat from Diesel run down stream.

MP steam generation about 6 MT/hr at current DHDT t’ put operation.

Diesel Run down temperature reduced from 190 -200 deg C to 160-165 deg C.

Saving: 3200 SRFT/yr (Equivalent to net 6 Mt/hr steam saving)

MP Steam Gen

About 6 MT/hr


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INNOVATIVE PROJECT 3

Ascending WABT Profile in DHDT Reactors


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E-1

357°C

357°C

304°C

395°C

385°C

388°C

385°C

393°C

WABTWABTWABT

392°C385°C385°C

Furnace

R1 R2 R3


Quenching from hydrogen

BEFORE-FLAT PROFILE


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E-1

330°C

330°C

284°C

363°C

363°C

383°C

382°C

393°C

WABTWABTWABT

389°C374°C353°C

Furnace

R1 R2 R3


Quenching from hydrogen

AFTER-Ascending Profile


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Ascending order WABT profile was maintained by reducing the intermediate quench

flow and allowing the adiabatic temperature rise in the catalyst bed.

With reduction of quench flow, equivalent flow was maintained across the RGC anti-

surge control valve by opening the same in steps.

Direct fuel saving (Saving of : 5400SRFT/yr )


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Certificates


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Certificates

ISO 9001 : QMS

ISO 14001: EMS


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Certificates

OHSAS : 18001

Occupation

Health and

Safety

Management


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Thank You

national award for excellence in energy management...

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