Bharat Oman Refineries Limited (BORL)

Transcription

1 19th National Award for Excellence in Energy Management 2018 Bharat Oman Refineries Limited (BORL) Bina, Madhya Pradesh Ambarish Mahajan Manager Sandeepan Nayak Assistant Manager

2 BORL Facilities at a Glance 1 Single Point Mooring (SPM) at Vadinar VLCCs BORL JV company of BPCL & Oman Oil Company (OOC) 4 6 MMTPA Refinery at Bina Crude Oil From Middle East Delhi 2 Crude Oil Terminal & Pumping System (COT) Vadinar Vadinar Kota Bina BPCL Marketing Terminal Numaligarh Refinery 5 Bina Despatch Terminal (BDT) 3 Vadinar- Bina 935 km Crude pipeline (VBPL) Mumbai Refinery BPCL Refineries Crude pipeline 6 Bina-Kota pipeline (BKPL) linking BPCL s existing piping network (265 km) Kochi Refinery Product pipelines Advantageously placed to meet product requirements in high demand zone

3 Refinery Configuration Complex configuration, proven technologies, mid-distillate refinery Commercial production started - Jun 2011 Refinery Process Process Capacities CRUDE CDU VDU RCO O VD LVGO HVGO GO MS-BLOCK HCU + DHT GAS LPG NAPHTHA SKO ATF HSD Euro-III HSD Euro-IV MS Euro-III MS Euro-IV Units Capacity (MMTPA) Capacity (BPSD) CDU/VDU FCHCU DHDT DCU Hydrogen Unit 0.07 Process Licensor ABB Lummus Technology DELAYED COKER VR LCGO HCGO & C Naphtha H 2 HYDROGEN SOUR GAS SULPHUR BLOCK SULFUR NHT CCR PENEX POWER PLANT PETCOKE SOUR WATER Sulphur Recovery Unit 2 x 180 TPD Nelson Complexity Index 10.3 An ISO 50001:2011 EnMS certified company

4 Captive Power Plant General Overview CFBC Boilers MADE BY: BHEL CAPACITY: 3 X 275 MT/hr VHP steam 110 Kg/cm 2 (Petcoke) CFBC Boilers 3 Nos To Refinery 3 X 33 MW STEAM TURBINE GENERATOR STGs From Grid (220kv) Utility Boiler Net 160 TPH Power Steam INSTALLED CAPACITY 99 MW 985 TPH IMPORT FROM GRID CAPABILITY 100 MW HP steam 40 Kg/cm 2 MP steam 18 Kg/cm 2 LP steam 5 Kg/cm 2 To Refinery

5 Specific Energy Consumption (SEC) - Electrical & Thermal Refinery Specific Electrical Energy Consumption for year is higher due to higher secondary unit throughput Specific Electrical Energy Consumption kwh/mt of Crude Processed Specific Thermal Energy Consumption kj/kg of Crude Processed Refinery Specific Thermal Energy Consumption is expressed in kj/kg of Crude Processed

6 MBN MBTU/BBL/NRGF National Benchmarking Specific Energy Consumption (SEC) Refinery Specific Energy Consumption measured in MBTU/BBL/NRGF (MBN) BORL SEC Indian PSU Refineries & BORL SEC Indian PSU Refineries & BORL Source: PPAC, BEE, CII website

7 Global Benchmarking Solomon Benchmarking : Energy Intensity Index (EII ) Participating in Solomon Benchmarking since 2014 every alternate calendar year Energy Intensity Index TM (EII ) - GOC2 Group Q4 Q3 Q2 Q EII 95.3 indicating substantial improvement in energy performance of BORL Implementation of Encon Measures Plan FY will bring EII to Q1 6

8 En-Con Projects in last 3 yrs Year No. of En- Con Projects Implemented Fuel Oil (MT/Yr) Savings Rs Lakhs/Yr Investment Payback Period Rs Lakhs Months No. of ZERO INVESTEMENT En-Con Projects Total Any small saving in energy significantly impacts OP-Ex 7

9 Energy Conservation Plan: FY Sr. No En-con Plan FY CDU heater efficiency enhancement by implementation of VDU hot well gases conditioning system. Investment - 4 Rs Cr, Planned & Completed in Installation of step less control in Make Up Gas compressor Investment Rs Cr, Planned & Completed in Insulation improvement in Delayed Coker unit with improved type of insulation. Investment - 2 Rs Cr, Plan Installation of Power Recovery Turbine in Hydrocracker 1st stage reactor feed pump. Investment - 13 Rs Cr, Plan Installation of flash steam recovery system in DCU Investment Rs Cr, Plan Installation of LP steam generator in Hydrocracker light diesel product stream. Investment Rs Cr, Plan Installations of Crude Preflash drum in CDU to increase energy efficiency. Investment - 25 Rs Cr, Plan Est. SRF (MT/day) Total Saving Potential SRFT/day 21.6

10 Energy Conservation Plan: FY Sr. No En-con Plan FY Implementation of process gas waste heat recovery in HGU to pre-heat DM water. Investment Rs Cr, Plan Installation of LRVP (Liquid Ring Vacuum Pump) in Vacuum Column Overhead Ejector System. Investment - 29 Rs Cr, Plan Implementation of Flare Gas Recovery System. Investment - 10 Rs Cr, Plan Installation of Rooftop Solar power system of 140 kw on Admin Building car parking area rooftop. Investment - 1 Rs Cr, Plan Installation of Solar Water Heater (SWH) system of 3*500 LPD hot water on Refinery Canteen. Investment Rs Cr, Plan Est. SRF (MT/day) Total Investment 94 Rs Cr (0.5% of Turnover), Total Saving Potential SRFT/day

11 Energy Conservation Measures Implemented Sr. No. 1 En-con Measures implemented * Power Consumption reduction: I. IFO & RFO inter connection in CDU/VDU is completed which reduced power consumption by 24 kw by stopping one IFO pump II. III. IV. CCR single Net gas compressor- B operation after overhauling and modification, saved power 0.8 MW. Installation and commissioning of Air cooler cum humidifier in Laboratory, saved power 8.66 KW by reducing no. of compressor running. DCU BCR sump pump ( 14-PA-136 A/B ) impeller modification to reduce pump running hour, saved power 19.2 kw V. Installation and commissioning of 9 nos of flameproof local control station in Laboratory for the energy conservation in Fume Hood operation Net Reduction kw Total Power Reduction 871.2

12 Energy Conservation Measures Implemented Sr. No. 1 En-con Measures implemented * VI. Installed ETC based Solar Water heating system of 8x500 LPD for providing preheated water to bathing purpose in township Net Reduction kw Total Power Reduction Steam Consumption reduction: I. Installation of new control valve in secondary MP steam to Hydrocarbon Flare tip to optimized MP steam flow. Insulation Improvement reduction: I. Heat Loss minimisation by providing removable pad type insulation to process heat exchangers end covers in CDU/VDU. Steam reduction MT 0.1 FO MT/day 1.9 Total Fuel Consumption Reduction 1.9 * 20 nos Zero investment EnCon measures are not listed. Equivalent Fuel Oil saving ~ MT/Yr ~ 2513 Rs Lakhs/yr

13 Energy Conservation Measures Implemented Sr. No. En-con Measures implemented Power Consumption reduction: I. CDU - Single fan operation in CDU Heater FD Fan Net Reduction kw 85 II. MSB - Single fan operation in HOH Heater FD Fan 30 III. HCU - Stopping of Sour water Pump 16-PA-CF-813 A/B 9 1 IV. DHT - Parallel pump operation converted to single pump in product stripper reflux pump (701 A/B) & Fractionator bottom pumps 705A/B 280 V. Refinery CT - Low weight coupling installation in one of the refinery cooling tower fan 0.3 VI. VII. Township 244 nos 18w CFL replaced with 9w LED bulb, 63 nos 36w Tube light replaced with 20w LED tube light BDT Solar Power Generation Started Total Power Reduction 641

14 Energy Conservation Measures Implemented Sr. No. En-con Measures implemented Steam Consumption reduction: I. ARU - Amine regeneration column LP steam reduction to 41 TPH from 45 TPH by optimization Net Reduction TPH 3.2 II. DCU - Velocity steam reduced by 25 kg/hr in all passes resulted in steam consumption reduction by 100 kg/hr III. VDU - Ejector steam consumption reduction by 1 TPH 0.3 IV. SRU - Implementation of Flash steam and Condensate recovery System. 2.1 TPH flash steam & 2.2 TPH condensate is being recovered. 0.5 V. HCU - RGC Lube Oil Turbine leak off steam routed to LP steam header, saved 0.5 TPH steam 0.2 Sub Total 4.3

15 Energy Conservation Measures Implemented Sr. No. 2 En-con Measures implemented Steam Consumption reduction: VI. All - CDU/VDU, MSB, HCU/DHT, HGU, DCU, CPP, SRU, Offsite & Utilities steam system management by specialised agency, 10 TPH steam loss reduced. Net Reduction TPH Total Steam Consumption Reduction 6.1 Insulation Improvement reduction: FO MT/day I. VDU Column insulation improvement reduced 0.06 MMkcal/hr heat loss. II. HGU-Reformer APH and combustion air duct insulation improvement- 0.5 MMkcal/hr heat loss reduced Total Fuel Consumption Reduction 1.3 Equivalent Fuel Oil saving ~ 5439 MT/Yr ~ 1565 Rs Lakhs/yr

16 Energy Conservation Measures Implemented Sr. No. 1 En-con Measures implemented Power Consumption reduction: I. ETP power reduction by blower operation optimization, reduced sp. power by 6%. II. III. IV. Installation of Stepless controller in one of Make Up Gas compressor in HCU Refinery Nos street light pole fixtures-hpsv-150w replaced, High Mast fixtures-24 nos HPSV-400W, 300 nos 36W Florescent tube lights repalced with LED lights. Single FD fan operation in HCU-DHT 501/701 heater. V. HCU filter backwash one fin fan stopped VI. VII. Utility Boiler seal air fan on standby mode & blow down transfer pump on manual mode resulted into power saving. Low weight coupling installation in Refinery Cooling Tower fans. Net Reduction kw Total Power Reduction

17 Energy Conservation Measures Implemented Sr. No En-con Measures implemented Steam Consumption reduction: I. All - CDU/VDU, MSB, HCU/DHT, HGU, DCU, CPP, SRU, Offsite & Utilities steam system management by specialised agency, 2 TPH steam loss reduced. II. ARU - Amine regeneration column LP steam reduction to 39 TPH from 42 TPH by optimisation Net Reduction TPH Total Steam Consumption Reduction 5 FO MT/ day Fuel consumption reduction: I. CDU heater efficiency enhancement by implementation of VDU hot well gases conditioning system. Insulation Improvement reduction: I. DCU Coke drum insulation improvement reduced 0.13 MMkcal/hr heat loss Total Fuel Consumption Reduction 0.96 Equivalent Fuel Oil saving ~ 4059 MT/Yr ~ 1310 Rs Lakhs/yr

18 Innovative Project 1: DCU Coke drum B insulation improvement Objective: Reduce energy loss & improve reliability by replacing conventional insulation with panel type insulation Trigger: Liquid yield improvement - Thermal cracking is an endothermic reaction, hence retention of heat with proper insulation is favourable for reaction. Reliability Cyclic expansion and contraction was resulting in damaged insulation. Radiation loss reduction Coke drum surface temperature was higher. Project Detail: Slotted cleats were welded with insulation rings, which allows the free movement (due to provision of slot) of insulation ring along with panels with respect to coke drum during the cyclic changes and increases the durability of insulation. 17

19 Innovative Project 1: Benefits DCU Coke drum B insulation improvement Drum surface temperature improved. 20 kg/hr FG saving in fired heater, Savings 0.34 Rs Cr/yr Liquid yield improvement. Invest 1.22 Rs Cr, Payback 3.7 Years CO2 Emission reduction 448 t CO2/yr This project is being replicated in DCU Coke drum A 18

20 Innovative Project 2: VDU hot well gases conditioning system to enhance CDU heater efficiency Objective: CDU heater efficiency enhancement by implementation of VDU hot well gases conditioning system Trigger : CDU heater APH outlet temperature was maintained above 167 o C to avoid the sulphur dew point corrosion. Project : Amine treatment of 10% H2S rich hot well gases to 10 ppm H2S. Low pressure drop structured packing amine column was installed as VDU off gas pressure was lower in the range of 0.1 Kg/cm2 CDU heater APH O/L temperature was reduced from 167 o C to 156 o C with higher air pre-heat resulted in higher heater efficiency. 19

21 Innovative Project 2: VDU hot well gases conditioning system to enhance CDU heater efficiency Benefits : CDU heater efficiency improved by 0.5%, 0.65 MTOE/day saving Stack SOx emission reduction. Investment - 4 Rs Cr Savings 70 Lakhs/yr CO2 Emission reduction 685 t CO2/yr 20

22 Innovative Project 3: Stepless control logic implementation in HCU MUG compressor Objective: Make-up gas (MUG) compressor spillback optimization for energy consumption Trigger : MUG Compressor was provided with three step control loading ( 50%, 80%, 100%), In between loading requirement was met with spillback opening with higher energy consumption. Project : Stepless capacity control logic was implemented by completely loading and/ or loading some of the valve on same cylinder to match the exact requirement of process with the compressed gas with no spill back and hence no loss of energy. 21

23 Innovative Project 3: Stepless control logic implementation in HCU MUG compressor Benefits : Power consumption reduction kw, 2.8 Rs Crs/yr Investment Rs Cr, Pay Back ~ 15 Month CO2 Emission reduction 3320 t CO2/yr This project is being replicated in Net gas compressor of Motor sprit block 22

24 Utilization of Renewable Energy Sources: Initiatives at BORL 4 MW Solar Power Plant at BORL generating units per day 10 kw Solar PV Panel in SV stations of VBPL pipeline Installed Solar Power based electric fencing to refinery as well as township boundary wall of 22 kms for security purpose. Invest 2 Rs Cr Installed Solar Water heating system Solar Wind hybrid power supply system for Campus video surveillance, Wi-Fi and LED based street light.

25 Utilization of waste as fuel: Waste gas generated in Vacuum Distillation Unit is used as fuel in Fired heater of Crude Distillation Unit. Waste gas called as Purge Gas generated in Hydrogen Generation Unit is used as fuel in HGU Reformer. Utilisation of waste gas as fuel saved SRFT of Fuel in 3 years Petcoke called as crude bottom product is being used as fuel in Circulating Fluidised Bed Combustion (CFBC) technology based Boilers.

26 tco2/ MT of Crude throughput GHG emission inventory trend t CO2 emission is calculated based on ISO methodology (3240 TMT) 0.39 (2492 TMT) 0.37 (2484 TMT) ~ 27% reduction in Specific CO2 emission in 3 years Effective Energy Management system, implementation of En-con measures & green initiatives helped BORL in reducing GHG emission. 25

27 Best Practices Implemented on Energy Front in Green Supply Chain: Management commitment to continual improvement in energy performance is demonstrated by; bringing energy efficiency in the design stage, purchasing energy efficient equipment, based on life cycle cost. Certification of EnMS ISO 50001:2011 within shortest time Steering committee formation for well structured reviews Promotion of participative energy conservation culture by launching platform like RISE & Managing Director Award Certification of ISO 9001:2015, ISO 14001:2015, ISO 45001:2018 Dedicated energy department BEE certified Energy Manager, EnMS auditor nos 03 Lead / 34 Internal Transport of Raw Material: Use of Drag Reducing Agent (DRA) & VFD to reduce energy consumption in pipeline & throughput maximization

28 Best Practices Implemented on Energy Front in Green Supply Chain: Manufacturing & Storage : Use of energy efficient design - max m heat integration Maximization of Hot Feed (85-94%), Condensate Recovery (80-85%) High efficiency fired heaters/boilers, Use of Glass APH, API 560 Low emissions - Double seal in tanks & pumps, LDAR Use of renewable resources Solar power plant, Solar water heater Use of APC for energy optimization, third party energy audit Hydrocarbon loss accounting as per IP method Participation in Global Benchmarking Fly ash brick is being utilized in all construction work. Extensive monitoring of high energy intensive equipment Ultrasonic flare flow meter in all units, VFDs in Fin Fans & ID/FD Product Transportation: Maximized product evacuation though pipeline

29 Greening at BORL: Water Conservation: Rain Water Harvesting pond with ground recharge facility within the refinery premises with solar lighting installation & RWH pits in township are developed. Recharge to groundwater ~ 26 TKL Sink for GHG Emission: 33% area covered under greenbelt 3 Lakhs samplings in refinery & 55,000 sampling in township 2 Lakhs samplings in nearby villages

30 Energy Management Team Dedicated Energy Department headed by Energy Manager who is BEE certified Energy Auditor Each area has Energy Coordinator Two tier mechanism of review: Energy performance & energy improvement schemes are monitored in Monthly review at unit level Quarterly review at Apex level chaired by MD, BORL. Encon Project Management Team is a cross functional team

31 Monitoring of Energy Conservation Project Prioritisation OFI Hopper Quick Wins Short Term Long term / Project Basis - Payback Immediate / ZERO Invest. 0 6 Months / Small Invest Months / Large Investment

32 Monitoring and Reporting Practices Sr. No. Energy Performance Indicators 1 Fuel & Loss Daily 2 Flare Loss Daily 3 Fired Heater Performance & CPP Performance Daily 4 Hot & Cold Feed Optimization Daily 5 Unit wise Specific Fuel, Power, Steam Consumption Daily 6 Equipment wise Steam Generation Daily 7 Refinery Steam Balance Daily 8 Refinery Specific Energy Consumption (MBN) Daily 9 Refinery Energy Intensity Index (EII) Daily Monitoring Frequency 10 Hydrocarbon Loss Accounting Daily/ Monthly To manage we have to control and to control we have to measure

33 Monitoring and Reporting Practices Energy Dashboard: Flare Monitoring: Unit EII monitoring

34 Monitoring and Reporting Practices Unit Specific Energy Consumption (MBN) monitoring graphic in DCS :

35 Monitoring and Reporting Refinery Energy Balance Monitoring : Daily Daily Unit Energy Balance indicates where the energy improvement opportunities are today.

36 ISO 50001:2011 Energy Management System (EnMS) Certification 35

37 Awards and Recognition Hon ble President of India Shri Ram Nath Kovind conferring the National Energy Conservation Award 2017, Managing Director, BORL Shri S S Sunderajan receiving the award at a ceremony conducted in Vigyan Bhavan, New Delhi on 14 th Dec 2017 Lowest Steam Leak award in OGCF 2015 from CHT MoP&NG at 20 th Refinery Technology Meet

38 Thank You BORL Fuelling Nation Bringing Cheers CII 18 th National Award 2017 Bhamashah Award - MP NHRDN CSR Competition-2016 award An ISO 9001, 14001, & company Frost & Sullivan Award for Environment & Op Excellence Leadership Project