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Indian oil corporation barauni refinery

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Indian oil corporation barauni refinery

  1. 1. 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 differentpetroleum products produced by Barauni Refinery are LPG, Naphtha, Motor spirit, SuperiorKerosene 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 WestBengal, Bihar, Nepal and part of U .P. Barauni Refinery – In harmony with nature
  2. 2. 20 (ii) Energy Consumption :Refining of crude oil being an energy intensive activity, the major chunk of expense in theprocess 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 tothe bottom line but also protection of environment and quality of life. Due efforts were made bythe refinery and various energy conservation measures like yield and energy optimisation ofdistillation units (AVU-I, II & III) & Coker-A & installation of high efficiency Gas Turbine. Oldconventional pneumatic systems used for operational controls have also been replaced withDistributed Control System in all process units and OM&S. These measures along with day today monitoring of fuel & loss helped to bring down the energy consumption level from 171MBTU/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. Barauni Refinery – In harmony with nature
  3. 3. 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 03-0420 (iii) Energy Conservation Commitment, Policy and Set Up :To conserve energy, optimisation of the operation of the process heaters and boilers andmaximum possible heat recovery from out going streams have been given utmost emphasis inday-to-day refinery operations. The efficient usage of utilities, optimisation of steam-powerbalance, and optimization of heat exchanger train have been the prime concern in the EnergyConservation area.As a broad classification the energy conservation activities have been grouped under long termand short term ones. The long-term activities are the high investment projects spread over along period. The short-term measures consist of continuous efforts for energy optimisation.The specific energy consumption is monitored daily/weekly/monthly for effective control. Theoptimisation of process conditions and implementation of energy conservation scheme is giventhe highest priority.Energy Conservation fortnight is celebrated every year from 15th Jan to 31st January. Variouscompletion like essay, slogan, poster on energy saving and cycle rally & in-house seminar isconducted. Barauni Refinery – In harmony with nature
  4. 4. The importance of energy conservation is emphasized through TPM (Total ProductiveMaintenance) by achieving zero breakdown, zero defect culture. Barauni Refinery has startedTPM implementation in October’2002 and Coker-A unit has been selected for implementation ofPilot model by April’2004. TPM was formally Kicked off on 30th Aug’2004 after successfulimplementation of Pilot Model at process unit. Refinery wide implementation of TPM is plannedto be completed by 2007 end.Right from the beginning Barauni Refinery has an exclusive Energy Conservation Cell formonitoring 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 Barauni Refinery – In harmony with nature
  5. 5. 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-IINew 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 anderadicated the use of 40 ata steam for that purpose. The system has also removed the thirdwater system for which a separate cooling tower was being operated.The incorporation of coalescer along with this system has also reduced the slop generationdecreasing the load on ETP and reducing the hydrocarbon loss. The HC recovered in thecoalescer are being directly routed to diesel pool. Estimated benefit of the installation ofVacuum ejector is 1496 SRFT/yr which is equivalent to Rs. 149.6 Lakhs / Year. Barauni Refinery – In harmony with nature
  6. 6. 3. Commissioning of Air Coolers in AVU-IISince inception of the unit, the overhead systems ofK-1 and K-2 were equipped with water condensersfor condensing the overhead vapours from K-1 andK-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 theoverhead vapors cooling tower was being operateThe condensed vapors from the air condensers are further cooled down in trim to bring downthe temperature of the condensate to 40°C.Provision of these air condensers has reduced the cooling water consumption; maintenancecost incurred to clean the water condensers on regular basis and has helped to increase theefficiency of the system. Estimated benefit of the installation of Vacuum ejector is 570SRFT/Yr. which is equivalent to Rs. 60 Lakhs / Year.4. Commissioning of APC in AVU-I / II / IIIAdvanced 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 ofoverall online process control for optimized operation based on objective functions provided.Based on the process conditions / disturbances it derives inferential predictive performanceand accordingly adjusts process conditions. A more steady and optimized operation isachieved. Estimated benefit of APC is 1900 SRFT /yr which is equivalent to Rs. 200Lakhs/Year. Barauni Refinery – In harmony with nature
  7. 7. 20 (v) Energy Conservation Plan & Targets:To improve the energy performance further, the following major projects are underimplementation / 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 2582With the implementation of above energy conservation projects, specific energy consumption ofthe refinery will about 112 MBTU/BBL/NRGF. Barauni Refinery – In harmony with nature
  8. 8. 20(vi) Environment Management System:Barauni Refinery has a full-fledged Environment Protection Cell. The worth noting is that thiscell was established 28 years back in 1975. In Indian oil, Environment Protection has alwaysremained a thrust area. The Environment Protection Cell having qualified engineer’scoordinates all the activities required to achieve continuous improvement in environmentalperformance related to Environmental Management in the Refinery. The goals and functions ofthe 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 Barauni Refinery – In harmony with nature
  9. 9. developed with in-house expertise and resources has lush green lawns large variety of treesand shrubs and the wonderful ECO pond where flora & fauna and aquatic life are thriving ontreated effluent. The surrounding tranquil environment of the ECO pond of park attractshundreds of migratory birds every winter. It is a testimony of refineries dedication to fosteringenvironmental excellence and enhancing quality of life in the region.Barauni Refinery had developed Environmental Management System conforming to theInternational Standards, ISO-14001 and Integrated the same with International QualityManagement Standard, ISO-9001:2000 and with the Occupational Health Management Systemconforming to OHSAS-18001:1999. Refinery thus developed an Integrated ManagementSystem called SHEQ System. SHEQ Policy, a set of objectives and time bond action plan areset for the continual improvement and customer satisfaction in the area of Safety, Health,Environment & Quality. ECOLOGICAL PARK ECOLOGICAL PARKTreated 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 Barauni Refinery – In harmony with nature
  10. 10. 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 thesource through use of low sulphur fuel in the furnaces and boilers. The stack emissions aremonitored periodically for SO2, NOx, CO and SPM and have been found to be well below thelimit 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 450Safety Management System:Barauni Refinery has an elaborate Safety Management System. Refinery is following stringentOil Industry Safety Directorate (OISD) standards and other Rules/ Acts as applicable. PeriodicSafety Audit of the facilities and system is carried out. Each recommendation’s status isthoroughly discussed in the monthly Health & Safety Committee Meeting chaired by the topmost official of the company. No efforts are spared to fulfill recommendations arising duringSafety Audit, in shortest possible time.To take care of the Safety of the refinery and surrounding and to minimise the impact of theprobable emergencies, viz fire, explosion, toxic gas release etc., Refinery has prepared On-SiteDisaster Management Plan and Off- Site Disaster Management Plan, and both are dulyapproved by competent authority. Material Safety Data Sheet (MSDS) consisting of paramountproperties of chemicals & their safe handling is a part of Disaster Management Plan. To checkthe efficiency and bring improvement in the plan, periodic On-Site & Off Site mock drills areconducted. Barauni Refinery – In harmony with nature
  11. 11. ----- End -----Barauni Refinery – In harmony with nature
  14. 14. 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. Barauni Refinery – In Harmony With Nature
  15. 15. 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 Barauni Refinery – In Harmony With Nature
  16. 16. 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. Barauni Refinery – In Harmony With Nature
  17. 17. 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.Technical & Financial Analysis Made :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 MTB. 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 Barauni Refinery – In Harmony With Nature
  18. 18. (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. Barauni Refinery – In Harmony With Nature
  19. 19. 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. Technical & Financial Analysis Made : 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. Barauni Refinery – In Harmony With Nature

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