Indian oil corporation barauni refinery

BARAUNI REFINERY – INDIAN OIL CORPORATION
Barauni (Bihar)

(i) Unit Profile
Barauni Refinery is the second Public Sector
Refinery of Indian Oil Corporation built in
collaboration with erstwhile USSR and limited
participation of Romania. It is located near
the northern bank of river Ganga in Begusarai
district of Bihar. The refinery went on stream
in the year 1964 and was formally
inaugurated by Prof. Humayun Kabir, the
then Union Minister for Petroleum &
Chemicals, Govt. of India on 15th
January,1965.

The installed capacity of crude oil processing
has been enhanced from 3.3 MMTPA to 6.0
MMTPA since Jan’2003 after commissioning
of process units like RFCCU, DHDT, HGU,
SRU, ARU & SWS.

During the year 2003-04, Barauni Refinery processed 4.3 MMTPA crude oil. The different
petroleum products produced by Barauni Refinery are LPG, Naphtha, Motor spirit, Superior
Kerosene Oil, High Speed Diesel, Light Diesel Oil, Raw Petroleum Coke & Sulphur.

Barauni Refinery caters to the Oil requirement of large number of customers of Northern West
Bengal, Bihar, Nepal and part of U .P.

Barauni Refinery – In harmony with nature

20 (ii) Energy Consumption :

Refining of crude oil being an energy intensive activity, the major chunk of expense in the
process is the energy cost. Therefore, the need of energy conservation is of utmost importance.
This leads to not only increase in profitability in the form of lower energy cost and adding on to
the bottom line but also protection of environment and quality of life. Due efforts were made by
the refinery and various energy conservation measures like yield and energy optimisation of
distillation units (AVU-I, II & III) & Coker-A & installation of high efficiency Gas Turbine. Old
conventional pneumatic systems used for operational controls have also been replaced with
Distributed Control System in all process units and OM&S. These measures along with day to
day monitoring of fuel & loss helped to bring down the energy consumption level from 171
MBTU/BBL/NRGF in 1990-91 to 133.8 in the year 2003-04.

UNIT 2001-02 2002-03 2003-04

CRUDE MMT 2.91 2.99 4.30

COKER T’PUT MMT 0.67 0.65 0.45

RFCCU MMT - 0.50 1.02

DHDT MMT - 0.71 2.17

HGU MMT - 0.04 0.92

PROCESSING COST RS / MT OF CRUDE

FUEL & LOSS % 6.99 11.4* 10.2

NRGF 2.8536 3.8312 3.8636

MBTU/BBL/NRGF 135.4 146.09 133.8

* Includes 1.25 % F&L towards BXP units(RFCCU / DHDT / HGU / SRU / ARU / AWS)
commissioning.


ENERGY + LOSS PERFORMANCE ENERGY COST
(MBTU / BBL / NRGF) (% OF MANUFACTURING COST)
150 45
146.09
39.6
145 40 38.3

140 35

135.4
135 133.8 30
26.9

130 25

125 20
01-02 02-03 03-04 01-02 02-03 03-04

20 (iii) Energy Conservation Commitment, Policy and Set Up :

To conserve energy, optimisation of the operation of the process heaters and boilers and
maximum possible heat recovery from out going streams have been given utmost emphasis in
day-to-day refinery operations. The efficient usage of utilities, optimisation of steam-power
balance, and optimization of heat exchanger train have been the prime concern in the Energy
Conservation area.

As a broad classification the energy conservation activities have been grouped under long term
and short term ones. The long-term activities are the high investment projects spread over a
long period. The short-term measures consist of continuous efforts for energy optimisation.

The specific energy consumption is monitored daily/weekly/monthly for effective control. The
optimisation of process conditions and implementation of energy conservation scheme is given
the highest priority.

Energy Conservation fortnight is celebrated every year from 15th Jan to 31st January. Various
completion like essay, slogan, poster on energy saving and cycle rally & in-house seminar is
conducted.


The importance of energy conservation is emphasized through TPM (Total Productive
Maintenance) by achieving zero breakdown, zero defect culture. Barauni Refinery has started
TPM implementation in October’2002 and Coker-A unit has been selected for implementation of
Pilot model by April’2004. TPM was formally Kicked off on 30th Aug’2004 after successful
implementation of Pilot Model at process unit. Refinery wide implementation of TPM is planned
to be completed by 2007 end.

Right from the beginning Barauni Refinery has an exclusive Energy Conservation Cell for
monitoring energy consumption and implementation of ENCON measures.

Energy Conservation Team Structure

UNIT HEAD
EXECUTIVE DIRECTOR

GENERAL
MANAGER (Tech)

DY. GENERAL
MANAGER (TS)

TA & ENCON CELL

Review existing energy level and Hydrocarbon loss.
Set Plant / Area wise targets and monitor the actual
performance.
Benchmark energy consumption and losses.
Carrying out audits / surprise checks.
Initiate ENCON projects, schemes etc.
Conducting surveys like:

Process Production Captive Power
Monitoring Cell Managers Plant, Utilities &
Offsites


20 (iv) Energy Conservation Achievements:

The major projects implemented during 2003-04 are as under:

1. Effective Utilisation of HRSG-II

A fuel efficient Gas Turbine system was
commissioned on 11th Dec '02 and Heat Recovery
Steam Generator was taken on range and put on
load with Gas Turbine on 21st Feb '03.

The estimated yearly benefit is 16649 SRFT /Yr.
which is equivalent to 1753 Lakhs / Year.

2. Installation of new Vacuum Ejector in AVU-II

New three stage ejectors comprising of two ejectors in each stage were commissioned in AVU-
II in Apr’2003. The O/H oil separated in hot-well goes through a coalescer for injection to Diesel.

Benefits:

The installation of ejectors has reduced the steam consumption from the earlier value and
eradicated the use of 40 ata steam for that purpose. The system has also removed the third
water system for which a separate cooling tower was being operated.

The incorporation of coalescer along with this system has also reduced the slop generation
decreasing the load on ETP and reducing the hydrocarbon loss. The HC recovered in the
coalescer are being directly routed to diesel pool. Estimated benefit of the installation of
Vacuum ejector is 1496 SRFT/yr which is equivalent to Rs. 149.6 Lakhs / Year.


3. Commissioning of Air Coolers in AVU-II

Since inception of the unit, the overhead systems of
K-1 and K-2 were equipped with water condensers
for condensing the overhead vapours from K-1 and
K-2.

During the M&I of AVU-I four air-condensers for K-1
(AC-101A/B/C/D) and four air-condensers for K-2
(AC-102A/B/C/D) were installed for condensing the
overhead vapors cooling tower was being operate

The condensed vapors from the air condensers are further cooled down in trim to bring down
the temperature of the condensate to 40°C.

Provision of these air condensers has reduced the cooling water consumption; maintenance
cost incurred to clean the water condensers on regular basis and has helped to increase the
efficiency of the system. Estimated benefit of the installation of Vacuum ejector is 570
SRFT/Yr. which is equivalent to Rs. 60 Lakhs / Year.

4. Commissioning of APC in AVU-I / II / III

Advanced Process Control (APC) has been implemented in Crude distillation units i.e. AVU-I /
II / III in Aug’03 at an investment cost of Rs. 71.25 Lakhs. Process control that has features of
overall online process control for optimized operation based on objective functions provided.
Based on the process conditions / disturbances it derives inferential predictive performance
and accordingly adjusts process conditions. A more steady and optimized operation is
achieved. Estimated benefit of APC is 1900 SRFT /yr which is equivalent to Rs. 200
Lakhs/Year.


20 (v) Energy Conservation Plan & Targets:

To improve the energy performance further, the following major projects are under
implementation / active consideration :

SL. PROJECTS / MODIFICATIONS TARGET ANNUAL ANNUAL
NO (YEAR) SAVINGS SAVINGS
(SRFT) (Rs. Lakhs)
1. Installation of BMS in TPS Boilers. 2005 180 18

2. Stoppage of operation of CRU cooling 2004 390 39
tower and connecting the CW system with
PCT.

3. Insulation of 9 nos. of RCO / LSHS tanks 2005 1800 180

4. Recovery of reactor blow down in Coker- 2005 1200 120
A

5. Heating of desalter wash water by 2005 600 60
desalter brine in AVU-I/II

6. Installation of TPI in ETP 2005 150 15

7. Heat recovery from RFO stream in Coker- 2005 1700 170
A by steam generation @ 3 MT/Hr

8. Revamping of heat exchanger network 2006 5000 500
and fractionation improvement in AVU-
I&II

9. Hydrogen recovery from CRU off gas 2005 13600 1360

10. Flare management with provision of LPG 2005 1200 120
vaporizer

Total 25820 2582

With the implementation of above energy conservation projects, specific energy consumption of
the refinery will about 112 MBTU/BBL/NRGF.


20(vi) Environment Management System:

Barauni Refinery has a full-fledged Environment Protection Cell. The worth noting is that this
cell was established 28 years back in 1975. In Indian oil, Environment Protection has always
remained a thrust area. The Environment Protection Cell having qualified engineer’s
coordinates all the activities required to achieve continuous improvement in environmental
performance related to Environmental Management in the Refinery. The goals and functions of
the cell are:
• To achieve reduction of wastes and
releases giving preference first to source
reduction, second to recycle / reuse and
third to treatment and thereby maintaining
effluent and emission standards within the
permissible limit and legislative
requirements.
• To obtain legislative sanctions viz. emission
and effluent discharge consent, NOC,
Environment Clearance for new projects and
to achieve compliance with NOC and EC
conditions.
• To establish prevention mechanisms by
application of engineering and operational
control.
• System development with environment
friendly. replacement/improvement within
and around the Refinery.
• Training / awareness programs in the areas SOME VIEWS OF ECOLOGICAL
of environment protection within and around PARK
the Refinery.
The Refinery has a beautiful ecological park spread over an area of 75 acres. The park


developed with in-house expertise and resources has lush green lawns large variety of trees
and shrubs and the wonderful ECO pond where flora & fauna and aquatic life are thriving on
treated effluent. The surrounding tranquil environment of the ECO pond of park attracts
hundreds of migratory birds every winter. It is a testimony of refineries dedication to fostering
environmental excellence and enhancing quality of life in the region.

Barauni Refinery had developed Environmental Management System conforming to the
International Standards, ISO-14001 and Integrated the same with International Quality
Management Standard, ISO-9001:2000 and with the Occupational Health Management System
conforming to OHSAS-18001:1999. Refinery thus developed an Integrated Management
System called SHEQ System. SHEQ Policy, a set of objectives and time bond action plan are
set for the continual improvement and customer satisfaction in the area of Safety, Health,
Environment & Quality.

ECOLOGICAL PARK ECOLOGICAL PARK
Treated Effluent Quality:
PARAMETERS MINAS LIMIT 2003-2004 (AVG.)
pH 6.0-8.5 7.55
OIL & GREASE, mg/litre 10 5.4
PHENOL, mg/litre 1.0 0.026
BOD, mg/litre 15 9.75
SULPHIDES, mg/litre 0.5 0.29
TSS, mg/litre 20 16.8


100% compliance of effluent quality with MINAS since 1990.
Maximum recycle of treated effluent. Nil discharge to river Ganges except in
Monsoon.
Emission Control:
The major air pollutant from the Refinery is SO2. The SO2 emissions are controlled right at the
source through use of low sulphur fuel in the furnaces and boilers. The stack emissions are
monitored periodically for SO2, NOx, CO and SPM and have been found to be well below the
limit specified by the CPCB as well as BSPCB.

UNIT STIPULATIONS ACTUAL
(AS PER MOE&F) SO2 EMISSION
SO2 EMISSION
AVU KG/ MT of crude processed 0.25 0.151
RFCCU KG/ MT of feed 2.5 0.28
TPS KG/HR (MAX.) 128 94
REFINERY KG/ HR 1080 450

Safety Management System:

Barauni Refinery has an elaborate Safety Management System. Refinery is following stringent
Oil Industry Safety Directorate (OISD) standards and other Rules/ Acts as applicable. Periodic
Safety Audit of the facilities and system is carried out. Each recommendation’s status is
thoroughly discussed in the monthly Health & Safety Committee Meeting chaired by the top
most official of the company. No efforts are spared to fulfill recommendations arising during
Safety Audit, in shortest possible time.

To take care of the Safety of the refinery and surrounding and to minimise the impact of the
probable emergencies, viz fire, explosion, toxic gas release etc., Refinery has prepared On-Site
Disaster Management Plan and Off- Site Disaster Management Plan, and both are duly
approved by competent authority. Material Safety Data Sheet (MSDS) consisting of paramount
properties of chemicals & their safe handling is a part of Disaster Management Plan. To check
the efficiency and bring improvement in the plan, periodic On-Site & Off Site mock drills are
conducted.


----- End -----


MAIN PRODUCTS

LPG : LIQUEFIED PETROLEUM GAS

MS : MOTOR SPIRIT

NAPHTHA : NAPHTHA

HSD : HIGH SPEED DIESEL

SKO : SUPERIOR KEROSENE OIL

MTO : MINERAL TURPENTINE OIL

LDO : LIGHT DIESEL OIL

LSHS : LOW SULPHUR HEAVY STOCK

RPC : RAW PETROLEUM COKE

CPC : CALCINED PETROLEUM COKE

P. EXT. : PHENOL EXTRACT

SL. WAX : SLACK WAX

Barauni Refinery – In Harmony With Nature

NAME OF PROCESS UNITS

AVU-I : ATMOSPHERIC & VACUUM UNIT-I

AVU-II : ATMOSPHERIC & VACUUM UNIT-II

AVUIII : ATMOSPHERIC & VACUUM UNIT-III

PEU : PHENOL EXTRACTION UNIT

SDU : SOLVENT DEWAXING UNIT

CCU : COKE CALCINATION UNIT

NSU : NAPHTHA SPLITTER UNIT

CRU : CATALYTIC REFORMER UNIT

RFCCU : RESID FLUID CATALYTIC CRACKING UNIT

DHDT : DIESEL HYDROTREATER UNIT

HGU : HYDROGEN GENERATION UNIT

SRU : SULPHUR RECOVERY UNIT

ARU : AMINE REGENERATION UNIT

SWS : SOUR WATER STRIPPER


IndianOil

Energy Policy
To be a World Class performer in energy management
By

• Adopting energy efficient and environment friendly
technologies.

• Benchmarking our performance with the best in the world
and endeavoring to be ahead.

• Promoting use of renewable sources of energy.

• Fostering a culture of participation and innovation amongst
stake holders for continual improvement in energy
conservation.

• Propagating the message of avoiding wastage of energy to
the community.


1. EFFECTIVE UTILISATION OF HRSG-II

Background :

To cater the power requirement of refinery @ 6.0 MMTPA after implementation of
Barauni Refinery Expansion Projects, a 20 MW Gas Turbine along with Heat Recovery
Steam Generator of capacity 48 MT/Hr (Pr.=40 ata , Temp.= 440oC) has been installed.
Fuel efficient Gas Turbine system was commissioned on 11th Dec '02 and Heat
Recovery Steam Generator (HRSG) was taken on range and put on load with Gas
Turbine on 21st Feb '03. The stabilised operation of HRSG was started in 2003-04.
Observation Made :

The steam generation through HRSG is 37 MT/Hr at a power load of 13 MW on Gas
Turbine.

Technical & Financial Analysis Made :

Power Load on Gas Turbine 13 MW
Fuel (Naphtha) consumption 5 MT/Hr
Equivalent SRFT 5.2 MT/Hr
0.40 MT/Mw
Steam Generation through HRSG 36 MT/Hr
Equivalent SRFT 2.6 MT/Hr

Net fuel consumption in Power generation through Gas Turbine 2.6 MT/Hr


0.20 MT/Mw
Savings SRFT by stopping one Boiler 16649 MT/Yr
1753 Rs. Lakh/Yr
Impact of implementation :

Operation of one boiler stopped.

2. INSTALLATION OF NEW VACUUM EJECTOR IN AVU-II

Background :

Steam jet ejectors were used for producing vacuum in the vacuum column with MP (10
ata) steam being used as the motive force.

The vacuum system utilised direct contact of cooling water with vacuum column
overhead vapour and steam coming out from column top resulting in mixing of
condensed oil and circulating water. This mixture was sent to a dedicated oily water
system (called as 3rd cooling water system). Since the emulsion of oil and water was very
difficult to break, this resulted in higher slop generation and subsequently higher
hydrocarbon loss.

Due to the use of direct contact type condensers a separate circulating water system
with cooling tower and API oil separator was required. The oil separated from these API
separators had to be recovered as slop oil and had to be reprocessed in the crude
distillation unit(s). It may also be noted that total recovery of oil was not feasible and
nearly 40% - 45% of the oil resulted into loss.

It is evident that the above mentioned system was energy inefficient and prone to higher
slop generation/ hydrocarbon loss. A separate cooling water system with hot and cold
water pumps, cooling tower fans and API oil separators had to be separately maintained
for vacuum producing system.

To reduce energy consumption and hydrocarbon loss the vacuum producing system of
AVU- II was revamped with the latest vacuum producing system consisting of the
following items -

Shell and tube type pre-condenser and primary inter-condenser using refinery
cooling water as cooling media.

Two stage steam ejector system.


Necessary piping and instrumentation.

Observation Made :

Elimination of direct contact type ejector condensers resulting in reduction of
hydrocarbon loss.

Savings in power consumption due to elimination of dedicated cooling water system
used for direct contact type condensers.


A. Reduction of Hydrocarbon Loss:
Sl. No. Particulars Quantity (MT/ Day)

1. Vacuum slop generation (@ 5000 MT/Day 9.6
T’put)
2. 30% of the vacuum slop skimmed off and 2.88
recovered in AVUs.
3. Slop carry over with 3rd system of circulating 6.72
water (1 – 2)
4. Slop recovery from API Separators (55%) 3.70
5. Hydrocarbon loss (3 – 4) 3.02
Annual Savings 997 MT

B. Reduction in Power Consumption:

Sl. No. Particulars Quantity (KWH)

Savings from removal of 3rd system of circulating water

1. Reduction of 2 Nos. of hot well pumps 2 X 75 KW

2. Reduction of 2 Nos. of cold water pumps 2 X 75 KW

3. Reduction of 3 Nos. of CT fans 3 X 28 KW

Total Power Consumption 234 KWH


(considering 1 hot well pump, 1 cold water
pump and 3 CT fans running)

Power consumption in revamped vacuum producing system -

1. 2 Nos. of hot well oil pumps 2 X 18.5 KW

2. 2 Nos. of oily water pumps 2 X 5.5 KW

Total power consumption 24 KWH
(considering 1 hot well oil pump and 1 oily
water pump running)
Net Power Consumption, (234 – 24) KWH 210 KWH

Net Annual Power Saving 1663 MW

Equivalent Annual Fuel Saving 499 MT

(considering 1 MW = 0.3 MT Fuel)

Total annual fuel saving and reduction of hydrocarbon loss due to revamp of vacuum
producing system in AVU-II (A + B) = 997+499 = 1496 MT

In monetary terms the savings is equivalent to Rupees 149.6 lakhs/ year.

Impact of implementation :

Reduction of power consumption and hydrocarbon loss.

3. COMMISSIONING OF AIR COOLERS IN AVU-II

Background :

Since inception of the unit, the overhead systems of K-1 and K-2 were equipped with
water condensers for condensing the overhead vapours from K-1 and K-2.

During the M&I of AVU-II four air-condensers for K-1 (AC-101A/B/C/D) and four air-
condensers for K-2 (AC-102A/B/C/D) were installed for condensing the overhead vapors.


Observation Made :

Provision of these air condensers has
reduced the cooling water consumption,
maintenance cost incurred to clean the
water condensers on regular basis and has
helped to increase the efficiency of the
system.


Estimated benefit of the installation of Vacuum ejector is 570 SRFT/Yr which is
equivalent to Rs. 60 Lakhs / Year.

4. COMMISSIONING OF APC IN AVU-I / II / III

Advanced Process Control (APC) has been implemented in Crude distillation units i.e.
AVU-I / II / III in Aug’03 at an investment cost of Rs. 71.25 Lakhs. Process control that
has features of overall online process control for optimized operation based on objective
functions provided. Based on the process conditions / disturbances it derives inferential
predictive performance and accordingly adjusts process conditions. A more steady and
optimized operation is achieved. Estimated benefit of APC is 1900 SRFT /yr which is
equivalent to Rs. 200 Lakhs/Year.


BLOCK FLOW DIAGRAM OF PROCESS / PRODUCTION UNITS OF BARAUNI REFINERY
FUEL GAS

LPG

CRU
MS

NAPHTHA

KEROSEN
AVU
H2
I/ PLANT

CRUDE II /
DHDT HSD
III

COKER LRU
–A
/
B IFO

RPC

ATU/SRU
FCCU
LPG MERICHEM SULPHURE

GASOLINE MERICHEM

Indian oil corporation barauni refinery

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