national award for excellence in energy management...
TRANSCRIPT
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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)
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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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ENCON- Schemes: 2014-15
S No. ENCON SCHEMESSRFT/Year
Completed on
Investment(Rs. Million)
/ 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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ENCON- Schemes: 2014-15
S No. ENCON SCHEMESSRFT/Year
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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ENCON Schemescompleted in 2015-16
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ENCON- Schemes: 2015-16
S No. ENCON SCHEMESSRFT/Year
Completed on
Investment(Rs. Million)
/ 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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ENCON- Schemes: 2015-16
S No. ENCON SCHEMESSRFT/Year
Completed on
Investment(Rs. Million)
/ 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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ENCON- Schemes: 2015-16
S No. ENCON SCHEMESSRFT/Year
Completed on
Investment(Rs. Million)
/ 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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ENCON Schemescompleted in 2016-17
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ENCON- Schemes: 2016-17
S No. ENCON SCHEMESSRFT/Year
Completed on
Investment(Rs. Million)
/ 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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ENCON- Schemes: 2016-17
S No. ENCON SCHEMESSRFT/Year
Completed on
Investment(Rs. Million)
/ 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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ENCON- Schemes: 2016-17
S No. ENCON SCHEMESSRFT/Year
Completed on
Investment(Rs. Million)
/ 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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ENCON- Schemes: 2017-18
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
Coker-A Single Furnace Operation
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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
Coker-A Single Furnace Operation
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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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Coker-A Single Furnace Operation
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
Installation of Kettle Type Heat Exchanger in DHDT
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Installation of Kettle Type Heat Exchanger in DHDT
#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
Modifications / Benefits:
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
Ascending WABT Profile in DHDT Reactors
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
Ascending WABT Profile in DHDT Reactors
Quenching from hydrogen
AFTER-Ascending Profile
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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 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