National Award For Excellence in Energy Management 2017

Transcription

1 National Award For Excellence in Energy Management 2017 PRESENTATION BY BARAUNI REFINERY INDIAN OIL CORPORATION LIMITED 30,31 August & 1 Sept 2017 Hyderabad International Convention Centre -in harmony with nature 1

2 PRESENTATION AGENDA Company Profile. 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 Utilization of Renewable energy. Utilization of waste as fuel. GHG emission Innovative Projects -in harmony with nature 2

3 Indian Oil Corporation: The Future of Indian Energy Strong Support from the Government of India Government nominated Directors on IOC Board 11 Refineries out of 23 Indian Refineries Largest Refiner in the Country 11 refineries with 80.7 MMTPA Capacity Nearly 35 % of National Refining capacity Pan-India Pipeline Infrastructure 13,000+ km pipelines for crude oil, products and natural gas with a total capacity of 93.7 MMTPA & 9.5 MMSCMD respectively Leading Market Share Across Portfolio ~50 % petroleum market share with over touch points Integrated Operations Across the entire Energy Value Chain 2nd largest domestic player in Petrochemicals Strong Focus on Innovation Through R&D and Alternate Energy Sources Overall 454 patents and growing New focus on Alternate and Renewable Energy (Wind, Solar, Biofuels, Nuclear) Driven by a Management Team That has Delivered Results Consistent growth and profitability Note: Company Filings and Petroleum Planning and Analysis Cell ( USD-INR: (as on March 31, 2015) -in harmony with nature 3 3

4 UNITS Units at CAPACITY (MMTPA) Year of Commissioning Licenser Mother Units AVU-I Russian AVU-II Russian AVU-III In-house Secondary Processing Units COKER-A Russian COKER-B EIL RFCCU SWEC HGU Haldor Topsoe HGU Linde SRU 2 X 40 MT/day 2002 Stork Biturox Pörner Catalytic Reforming Unit IFP DHDT UOP MS Quality Upgradation Unit NHDT Axens ISOM Axens SHU Axens HDS Axens RSU Axens -in harmony with nature 4

5 POWER & STEAM GENERATION FACILITIES 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,MW 12 STG-3,MW 12.5 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 PROCESS COOLING TOWER,M3/HR CRU COOLING TOWER, M3/HR 1200 TPS COOLING TOWER, M3/HR in harmony with nature 5

6 CRU FUEL GAS LPG MS SRN SKO H 2 PLANT New H2 Unit CRUDE DHDT HSD MSQ VU-I AVU-II AVU-III COKER A/B LRU LDO LSHS RPC FLOW DIAGRAM RFCCU ARU/SRU LPG MEROX SULPHUR CBFS BITUROX -in harmony with nature GASOLINE MEROX 6 BITUMEN

7 Projects coming up in Barauni refinery 1. Process units for BS-IV compliance: New CCR,Naphtha hydrotreater Revamp, New Prime G, DHDT revamp 2.9 MMTPA to 3.3 MMTPA 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) New FGC RO Plant IndJet BS-IV/V projects 1327 All figs in ` Cr. Barauni expansion Project to 9 MMTPA: Rs Cr. -in harmony with nature 7

8 Energy & Loss Performance -in harmony with nature 8

9 CRUDE T PUT (TMT) CRUDE T PUT Design Actual M&I Shut down for AVU III Highest Ever Th put 6526 APR 17 TO JULY YEAR Capacity Utilization: ~ 108% of design -in harmony with nature 9

10 MBTU/Bbl/NGRF SPECIFIC ENERGY CONSUMPTION [MBN] % ACTUAL % % APR 17 TO JULY Year Rate of reduction: ~ 3% per annum is under PAT II and target for MBN : in harmony with nature 10

11 Energy Intensity Index EII Solomon Global Benchmarking Comparison of Energy Intensity Index Solomon Global Benchmarking % Year Barauni refinery average Asia pacific average -in harmony with nature 11

12 ENCON Schemes completed in in harmony with nature 12

13 ENCON- Schemes: S No. 1 ENCON SCHEMES DHDT Stabilizer Off gas (lower H2 content) routed to RFCCU WGC instead of DOG PSA 2 CRU O/G directly routing to DHDT Make up gas header by-passing K-5 Compressor SRFT/Year Completed on 1320 Apr 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 May 14 Make up water heater (MUWH) in HRSG-II June 14 6 Reduction in Gas / Oil ratio in NHDT (MSQ) to reduced RGC load from 50% to 25% 7 Retrieval of intermediate gland and rear gland steam of TG July July 14 -in harmony with nature 13

14 ENCON- Schemes: S No. ENCON SCHEMES SRFT/Year Completed on 8 Coker-A Single Furnace Operation 4100 Aug 14 9 Installation of Auto water drain system in Product tank draining. 360 Aug Lower Gas/Oil ratio & Ascending WABT profile in DHDT with Anti-surge Opening 5400 Nov Glass APH in AVU-I/II. 310 Nov Telescopic Insulation in Reformer tubes. 150 Nov Scheme for routing DHDT stripper off gas to LRU section. 400 Nov 14 -in harmony with nature 14

15 ENCON- Schemes: S No. ENCON SCHEMES SRFT/Year 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) 14 MP steam in RFCC naphtha splitter reboiler instead of HP steam Replacing HP steam in SHU splitter, NHDT stripper reboiler, ISOM stabilizer & SHU preheater with MP steam 15 Step-less capacity control system in second MUG compressor (702-K-02 B) of DHDT Total Completed on June 14 Nov 14 Mar Feb 15 -in harmony with nature 15

16 ENCON Schemes completed in in harmony with nature 16

17 ENCON- Schemes: S ENCON SCHEMES No. Installation of Kettle type heat exchanger from DHDT 1 R/D SRFT/Year Completed on 3200 Mar-15 2 Routing of RSU off gas to RFCC WGC 2000 Jul-15 3 Routing of DHDT Stripper off gas to LRU section 300 Jul-15 Condensate recovery from Boiler-6 steam coil APH 4 (SCAPH) 160 Jul-15 5 Recovery of Boiler-6 CBD Flash steam 120 Aug Routing of MP steam from DHDT Kettle HE to RFCCU GSU Re-boiler Provision of routing of vapor heating condensate of coke chamber back to quench column 240 Aug Aug-15 -in harmony with nature 17

18 ENCON- Schemes: S No. ENCON SCHEMES SRFT/Year Completed on 8 RSU column completely bypassed 1580 Aug-15 9 Stoppage of steam in redundant IFO tanks in TPS 200 Aug Steam Trap System Management 300 Sep-15 Replacing HP steam in SHU, NHDT, ISOM & SHU 11 preheater with MP Steam 300 Dec-15 Load reduction of one air compressor by segregating 12 compressed header for RFCC & Coker 55 Dec-15 Optimization through column pressure reduction, 13 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 -in harmony with nature 18

19 ENCON- Schemes: S No. ENCON SCHEMES SRFT/Year Completed on 14 Replacement of normal tube lights with LED's 150 Nov Steam leak rectification through external agency 250 Jan-16 TOTAL in harmony with nature 19

20 ENCON Schemes completed in in harmony with nature 20

21 ENCON- Schemes: S No. 1 ENCON SCHEMES Rectification of faulty damper in AVU-II Crude Heater. SRFT/Year Completed on 1500 Oct-16 2 Low recycle ratio operation in Coker after revamp Jan-17 3 Steam traps system Management. 590 Oct-16 4 DHDT 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 7 Installation of oil catch pit in AVU I/II to recover Desalter oil carry over 50 Feb-17 -in harmony with nature 21

22 ENCON- Schemes: S No. ENCON SCHEMES SRFT/Year Completed on 8 DIH pressure reduction from 5.1 to 4.5 kg/cm2) 300 Jul Compressed air interconnection scheme with N2 unit Segregation of facilities for processing slop in AVU I/II/III and Coker Commissioning of scheme for routing of off-spec during AVU start up to crude tank Scheme for LP steam header connection between Units & TPS Segregated high pressure dedicated service air line installed for the critical service 400 Oct-16 - Jun Jul Apr Apr Solarization of non plant building 280 Mar-17 -in harmony with nature 22

23 ENCON- Schemes: S No. ENCON SCHEMES SRFT/Year Completed on 15 Use of LED lights (replacement of 4000 tube lights) 50 Feb-17 Total in harmony with nature 23

24 ENCON Schemes Completed / Planned in in harmony with nature 24

25 ENCON- Schemes: S No. ENCON SCHEMES SRFT /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 3 Compressed air & N2 leak survey through external agency 250 Completed in Jun-17 4 MFM in LPG transfer line to/from Bottling Plant 100 Completed in Jun-17 5 Closed 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 Desalter study by the external agency (Slop st phase completed. reduction) Target: Dec-17 Total in harmony with nature 25

26 Long Term ENCON- Schemes & Future Target S No. ENCON SCHEMES SRFT/Year 1 Utilization of Organic Rankine cycle for low level heat recovery from DHDT run down Completion by 3000 Dec-19 2 Green cooling tower in the new projects 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 : 75.5 MBN Outlook for : 75.0 PAT Target for : in harmony with nature 26

27 Energy Monitoring at Setting Target Energy Per Unit T put Implementation kwh/fuel ration MBN St./Fuel ratio Action plan Identfn. Comp. with Best / design Val. Gap Analysis Tar. Act. -in harmony with nature 27

28 Energy Monitoring at Critical Parameters Monitoring Format S. No. Energy Parameter Frequency 1 Preheat of units Daily 2 Stack temperature Daily 3 Flare monitoring Daily 4 GT/STG/TPS/Process Heater efficiency Daily 5 Steam Power balance Daily Compressors Spill back 6 opening Daily 7 Fuel & loss Balance Daily Specific Energy Consumption 8 monitoring (Unit wise) Daily Design /Benchma rking Actual Action plan -in harmony with nature 28

29 Best Practices followed at S. No. Best Practices Frequency 1 Generation of Daily ENCON report Daily 2 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 8 Compressor/Motors/Pumps/Blower performance survey Monthly 9 Ejector performance check Quarterly 10 Setting monthly targets based on previous performances/ theoretical, monitoring & Review by Management for ENCON parameters vis a vis targets Weekly / Monthly -in harmony with nature 29

30 Utilization of Renewable Energy Sources (SOLAR PANEL) Year New Installation Annual Energy Generated KW 23.2 MW MW MW MW (Under installation) -in harmony with nature 30

31 Fresh Water Consumption % reduction in 5 years % reduction in 3 years (till FW consumption (m3/hr) Fresh Water Consumption / MT of Crude (m3/mt) Feb'17) Additional water demand for MSQ facilities Commissioning of Modernized ETP in harmony with nature 31

32 Green House Gas Emission, (GHG): Fresh water consumption. Fresh water consumption reduced by 4.5 % in over last year through various water conservation schemes. Rain Water Harvesting: 14 nos. of Rain water harvesting projects have been implemented in refinery and township since Effluent Quality Improvement : MINAS standard as given by MOE&F is complied through ETP / BTP modernization project. Water Efficient Process: 100 % reuse of treated effluent water inside refinery. Green House Gas Emission, (GHG): For :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 and township for reduction in GHG during in harmony with nature 32

33 MT PER ANNUM Utilization of Waste as fuel Sources Flare Gas Recovered Waste fuel Utilization in MT Year Rate of Increase: ~ 3.5 % per annum -in harmony with nature 33

34 Comparison of CO2 E(MT) GHG Emission at CO2 E(MT) CO2 Emission (* 10^5 MT) Increase due to increase in processing of Crude -in harmony with nature 34

35 Carbon Emission Index Global Benchmarking -Carbon Emission Index Reduction by ~2.5% Year 2016 Barauni refinery average Asia pacific average -in harmony with nature 35

36 INNOVATIVE PROJECTS IMPLEMENTED -in harmony with nature 36

37 Coker-A Single Furnace Operation Modifications / Benefits: Coker-A Transfer line modifications done & Single furnace operation implemented on 11 th Dec 14. 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 ) Transfer line Modifications COKER-A FG 120d0h0m0s /3/ :10:04 1/31/ :10: FG Consumption in F-01A/F-01B kg/hr FG Consumption in F-01A kg/hr Furnace F-01B S/D 0 #1 (R) BRA.3FT 1303.PV 11/13/ :48: M3/HR (Raw) FG FLOW T O COKER_A FURNACE ** #2 (R) BRA.3FT 1403.PV 11/13/ :48: (Raw) FG FLOW T O COKER_B FURNACE Won best Kaizen award on 31 st July 15 conducted by CII -in harmony with nature 37 37

38 Ascending WABT Profile in DHDT Reactors Modifications / Benefits: 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 antisurge control valve by opening the same in steps. Direct fuel saving (Saving of : 5400SRFT/yr ) -in harmony with nature 38 38

39 Installation of Kettle Type Heat Exchanger in DHDT Modifications / Benefits: Kettle Heat Exchanger installed in DHDT to recover heat from Diesel run down stream. MP steam generation 5-10 MT/hr at current DHDT t put operation. Diesel Run down temperature reduced from deg C to deg C. Saving: 3200 SRFT/yr (Equivalent to net 6 Mt/hr steam saving) New Plot 45d0h0m0s /7/ :41:16 8/21/ :41: MP Steam Gen 5-10 MT/hr ** 0 #1 (R) BRA.702FI5202.PV 7/17/ :47: DEGC (Raw) MP STEAM GENERATION EX E-25 -in harmony with nature 39 39

40 Thank You -in harmony with nature 40