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ESSAR OIL LIMITED –Excellence in Energy Management-2017

1

Essar Oil Facilities at Vadinar site

EOL 20 MMTPA Refinery

11.8 Complexity

Oil Terminal - Jetty and SBM Operations

CPP (Captive Power Plant) – 600 MW

2

VGO MHC

DHDT

DCU

ISOM

CDU 2

CDU

CN

Blending

Mangala

HMU - I

HMU-2

Ultra Heavy

Crude

ARU/

SRUSulfur

Vadinar Refinery Process Flow

3

• Tallest crude column (90 metres height, 76 trays)

CDU – 18 MMTPA

• Low pressure steam ejectors & vacuum

VDU

• Converted to CDU from VBU.

• Capable to process ultra heavy crude on standalone basis.

CDU-II- 2 MMTPA

• Very high pressure hydro treatment

• Capable of producing Euro V diesel

DHDT- 4.0 MMPTA

• 6 Coker drums

• One of the largest Coker unit in the world

DCU- 7.5 MMTPA

• First refinery to use Coal fired Boilers for meeting Steam and power demands of the refinery

CPP (Captive power plant)

• 2 Stage Regenerators

• Running on Maximizing Middle Distillate Mode

FCCU- 3.9 MMTPA

• Producing Reformate with 101 RON

NHT/CCR- 1.5/0.9 MMTPA

• Capable to processing feed with 5% Benzene and 10% C7+

ISOM Unit- 0.7 MMTPA

• Converted to Mild Hydrocracker in Sept’2015 Turnaround Shutdown

VGO-MHC- 6.5 MMTPA

4

UNIQUE DESIGN FEATURES

Specific Energy Consumption of EOL

Refinery’s SEC monitored in terms of MBN (MBTU/KBBL/NRGF – as perCHT method). It has reduced from 63.84 to 58.69

5

63.8462.77

58.69

55

60

65

2014-15 2015-16 2016-17

MB

N

MBN (MBTU/KBBL/NRGF )

Comparison of Specific Energy Consumption with Indian Refineries:

6Data Source : Ready Reckoner Jun’17 on www.ppac.org.in

58

.7 64

.8 72

.3

72

.5

74

.8

78

.9

79

.6

80

.5

81

.4

84

.4

86

.3

87

.9

90

.3

92

.5 11

1.1

11

4.2

11

7.9

11

8.5

20.0

40.0

60.0

80.0

100.0

120.0

140.0

MB

N

SEC of Indian Refineries FY 2016-17

Note: Reliance, HMEL & BORL MBN data not available

Specific Energy Consumption of EOL -Comparison with other Indian Refineries

Specific Energy Consumption of EOL-Global Benchmarking

Data Source : Global benchmarking study conducted by Solomon for EOL.

92.00

80.01

78.0032

10

1

2

3

4

75.00

80.00

85.00

90.00

95.00

2013 2014 2016

Qu

arti

le

EII

1

Refinery’s SEC monitored in terms of EII (Energy Intensity Index)It has reduced from 92.00 to 78.00

LIST OF EnCON PROJECTS IN LAST 3 YEARS (with investment)

S.No PROJECT TITLE YEARSAVINGS

(Million Rs)INVESTMENT (Million Rs)

1HSD tank side stream mixture provision and stopping high capacity pump for circulation Saving: 133 MWH/Month

16-17 2.03 0.50

2Replacement of total 500 conventional lamps with high efficiency LED lamps• Power saving of 82.26 KWH

16-17 2.00 2.94

3PIT- Higher Capacity blending pumps replaced with lower capacity pumps • 40 MWH/Month

16-17 2.64 0.87

4PIT - Impeller trimming for MS-III to Dispatch transfer pumps • saving - 11 kwh

16-17 0.53 0.08

8


S.No

PROJECT TITLE YEARSAVINGS


5VFD drive installation in both boilers bottom ash submerged drag Chain conveyor• Saving 3.78 KWH

16-17 0.18 0.05

6

Steam trap management Amount for energy conservation invested in 1) Steam trap survey.2) High performance steam trap procurement.

16-17 11.65 0.16

7

Vacuum Gas Oil Mild Hydrocracking (VGO MHC) catalyst replacement.

After partial catalyst replacement conversion increased which also led to specific Energy reduction.

16-17 879.25 500.00

9


S.No PROJECT TITLE YEARSAVINGS


8

DCU - Replacement of MF overhead condenser• HP STEAM load has reduced by 5.96 T/HR • Saving - HPS 4.71 Gcal/hr

16-17 36.55 10.00

9

CDU-2 Pre heat improvement through Pinch study• FO Saving is 0.102 Tons/Hr, • Net savings : 1 Gcal/hr

16-17 8.08 42.42

10

Provision of Aerodynamic blade fin fan cooler in cooling tower. Replacement of fan blades of 5 utility cooling tower fans done during the year, 2 nos. balance• Saving 21.2 KWH/Fan i.e. 105 KWH/Hr

16-17 5.07 3.25

10


S.No



11 Cooling Tower stoppage 15-16 5.78 1.00

12Installation of liquid ring compressor in DCU unit

15-16 87.53 40.00

13Use of Hydrogen rich sat gas as HMU feed resulted in increased yield and reduction in fuel gas requirement

15-16 434.45 60.50

14 Low speed motor installation in CPP. 15-16 2.04 0.20

15Air compressor IGV set point changed.

15-16 5.78 0.05

16Feed preheat temperature increasedin CDU-I by heat integration.

14-15 129.95 0.45

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LIST OF EnCON PROJECTS IN LAST 3 YEARS (without investment)

SrNo


(Million Rs)

1Vacuum Residue (VR) run down temperature increase in CDU-2 unit.saving - 0.21 Gcal /hr

16-17 2.58

2Stoppage of Additional Lean Amine pump in DHDT unitPower saving of 185.2 KWH

16-17 8.94

3Blow down optimization in FCCU unit. Saving - .0.11 Gcal/Hr

16-17 5.93

4CPP - Optimisation of running drives through operational changes Additional running drives were stopped.

16-17 84.76

5Steam consumption reduction. By increasing amine concentration.Saving - 8 ton/hr

16-17 42.05

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S.No. PROJECT TITLE YEARSAVINGS

(Million Rs)

6One pump stopped in DM water transfer service by Pressure reduction.

15-16 1.79

7In Sulphur Recovery Unit, LP condenser Two fans of 22KW stopped.

15-16 0.23

8Cold VR from PIT to DCU one pump stopped.

15-16 1.84

9VGO Pressure Recovery Turbine-1 strainer replaced to improve the reliability and thus save energy

15-16 11.30

10Main Air blower amps reduced by 10 amps optimizing the IGV opening/closing blow off valve

15-16 0.54

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S.No. PROJECT TITLE YEARSAVINGS

(Million Rs)

11Lighting optimized in Mini HMU as the unit is in idle condition

15-16 0.54

12

In DCU, one condensate pump stoppedand 15 M3/hr cold condensate consumption reduced by using stripped water consumption.

15-16 0.31

13In DCU, LCGO side stripper MP steam reduced

15-16 3.80

14Low pressure operation in debutanizer of FCC

15-16 7.05

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S.No. PROJECT TITLE YEARSAVINGS (Million

Rs)

15DESAL condensate heat recovered to heat DM water and it reduced Cooling tower Heat load

14-15 18.73

16Base Refinery Acid Flare routed to Train-I Flare header

14-15 14.79

17Raw Water Treatment Plant DMF feed pump impeller trimmed

14-15 0.38

18Condensate Polishing Unit feed pump run load factor optimized

14-15 0.61

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TOTAL SAVINGS

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S.No. YearWith Investment

(Million Rs)Without Investment

(Million Rs)

1 16-17 947.98 144.26

2 15-16 535.58 27.40

3 14-15 129.95 34.51

Total Savings 1613.51 206.17

ROAD MAP

S.No PROJECT TITLE UNITENERGY SAVINGS

(MMcal/yr)

1Supply of lean amine to DHDT using VGO amine pump

DHDT 1205

2Installation of energy efficient fan blades in Utility cooling tower

Utility 1898

3Side stream mixture provision in pending one Diesel tank

PIT 228

4Provision of low RPM motor for sea cooling water return pump

Utility 2938

5Optimisation of operating parameters in DHDS Unit

DHDS 10911

6Increased in FCCU WGC compressor suction pressure

FCCU 1901

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ROAD MAP

S.No PROJECT TITLE UNITENERGY SAVINGS

(MMcal/yr)

7Motor replacement of Sea water supply pump 184P301 from 540kW to 710kW. Potential: 308 kWh

utility 2320

8182P118 Cold condensate supply pump impeller trimmingPotential: 55 kWh

utility 415

9Impeller trimming of raw crude booster pump .10-P-150 A/B/S Potential: 100kWh

CDU 753

10182P113 Desal water Feed to CPU unit Pump - impeller trimming . Potential: 79 kWh

Utility 595

11Installation of new smaller capacity product gas oil pump. Potential: 50 - 60 kWh.

DHDS 452

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ENERGY SAVING INNOVATIVE PROJECTS

1. DCU - Replacement of MF overhead condenser (E-100-C)

The Issue

• Main Fractionator one of the three condensers was fouled and was resulting in higher O/L temperature and increased molecular weight of the off gas and reduced liquid yield.

• As a result of the above steam required for the turbine of the off gas compressor was increasing.

Modification done

• Fouled condenser was replaced with new one during the available opportunity. This resulted in reduction of steam requirement for the turbine by 5.96 MT/Hr.

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DCU OVHD Exchanger Online Replacement

20

Main Fractionator

KOD

OVHD Receiver

HPS

E 100 -A E 100 -

B

WGCE 100 -C

60”

48”

36”

60”

48”

36”

Coke drum vapours


Energy Saving 4.71 MMkcal/Hr

Investment 10 Million INR.

Improvement 36.5 Million INR

Payback 3.30 Months

• Energy savings effect

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2. CDU-2 Pre heat improvement

The Issue

• Higher fuel consumption in CDU-02 heater resulting in higher skin

temperature of Atmospheric heater.

Existing Facility

• CDU-02 is designed for processing ultra-heavy crude at 70 Deg. C enters

CDU-02 B/L and after passing through exchanger train it is fad to the

heater at around 260 Deg.C for further heating the crude up to

fractionation temperature (350 Deg.C)

22

23

Crude

VR Quench to column FV

EFJK

Crude to heater

FVTV

VR from Pump

NEW

QR

LM NP

CDU-2 Pinch study

EFJK LM NP QR

Crude to heater

VR Quench to column

VR to MP Generation

VR from Pump

RCO

Crude

Old Config

Modified

VR to MP Generation

240 C

240 C

275 C

290 C


Modification donePinch analysis of the system was carried out. Result of the study suggested opportunity of utilising VR run down heat to pre heat the crude 2 Nos. of new exchangers were provided for crude V/S VR heat recovery the modification resulted in pre heat improvement of 15 Deg.C equivalent to 1.0 Gcal of heat which otherwise would have been lost to fin fan.

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Energy savings effect

Energy Saving 1.0 MMkcal/Hr

Investment 42.42 Million INR.

Improvement 8.08 Million INR

Payback 5.25 Years

Implementation of ISO 50001:2011

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S.No PROJECT DESCRIPTION YEAR

1PM analyser in CDU,VDU,CDU-II,FCCR and hooked up the same with CPCB server

2016

2Online BOD analyser installed at treated water line and hook up the same with CPCB server

2016

34 Ground water Recharge well-constructed inside the refinery at strategic locations for ground water recharge

2016

4Disposal of 1.4 MT Used Radiography Film from Refinery first time to actual user

2016

5Disposal of 190MT Oily Sludge by co-processing at M/s Ultratech Cement, Kovaya

2016

6 Detailed yearly Marine Monitoring by National Institute of Oceanography 2016

7 Disposal of 2315 MT Spent Ni-Co-Mo Catalyst 2016

81836 of plants were planted near Hazardous shed, near NKC,HMU,Northside area of Security control room to Fire station and South side of Crane over 1.53 acres of land

2016

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9 100 % ETP oily sludge is utilized in delayed coker unit 2015

10 100 % spent carbon utilized in power plant as a fuel 2015

11 Hook-up Stack, Ambient and Effluent Online analyser with CPCB server 2015

12LED display board installed at main gate for displaying Online data of ambient air quality, stack emission, effluent quality monitoring.

2015

13Measures have been taken like refilling printer toner cartridge to reduce e-waste generation

2015

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14FCC catalyst send to Cement industry and ceramic industry to use it along with raw material.

2014

15Adhering strictly to the guidelines from MoEF, EOL is working with Eco Recycling Limited, a company authorised by the CPCB to dispose of Electronic waste in an eco-friendly manner.

2014

16

5 rain water harvesting ponds at strategic locations are created for holding rainwater during monsoon which is being used for horticulture and improving ground water quality. Total capacity of these pond is 2,00,000 m3.

2014

172 existing reservoirs converted for rain water harvesting with Capacity: 1, 75, 000 m3.

2014

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GREEN BELT AT ESSAR

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Horticulture at Refinery (1064 Acres)

Type Description Total No.

Gre

en

Be

lt(8

47

Acre

s)

Mango trees 1,07,137

Pomegranate trees 1,960

Forest Species 1,91,298

Total Plants 3,00,395

Land

scape

(21

7 A

cres)

Refinery Landscape area(m2)

3,37,443

Avenue & Mass Plantation (m2)

3,59,955

Township & city based (m2)

1,82,204

Total Landscape 8,79,602

RENEWABLE ENERGY UTILIZATION

Solar photovoltaic cell in security

watch tower in remote location.

Small windmill installed to provide

lights to security cabin

Solar Operated Traffic Flasher Lights

installed near Refinery Main gate &

Township gate.

Solar Heater provided at Oil Club.

Emission free- electrically powered

Golf Carts and Fuel Free- Bicycles are

used in the Refinery.

Bio gas plant based on canteen food

waste.

Day light harvesting in warehouse.

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GHG Inventorisation

YearScope 1

emissions CO2e (MT)

Scope 2 emissions CO2e (MT)

Scope 3 emissions CO2e (MT)

CO2e MT (scope I +II)

2014 - 15 5.943 0.0049 0.0023 5.947

2015 - 16 5.581 0.0122 0.0020 5.593

2016 - 17 5.958 0.0025 0.0023 5.960

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Scope 1: Direct GHG emissionsScope 2: Electricity indirect GHG emissionsScope 3: Other indirect GHG emissions

Utilization of waste material as fuel-Bio Gas plant

Bio-gas plant is installed to dispose Kitchen waste, which also produce

Natural gas and manure. Natural gas is utilized as fuel in Kitchen and

manure in Greenbelt.

Capacity : 500 kg/Day kitchen waste

Bio Gas generation about 50 m3 / day equivalent to 20 Kg of LPG.

Utilization of waste material as fuel-Spent Carbon Disposal

Project Title :-

Disposal of Spent Carbon by reusing it as Alternate Fuel

in CPP coal based Boiler.

Spent catalyst disposal method:-

Spent Carbon is generated from Kerosene Merichem Unit, Sulphur

Recovery Unit and Utilities.

Normal mode of the Disposal is outside parties by incineration. It was

decided to dispose it by using as a fuel in CPP coal based Boilers

Total savings per year = Rs. 39,24,000

Utilization of waste material as fuel-Spent Carbon DisposalSavings due to disposal as fuel in CPP

Incineration cost saving Rs. 15000/MT (if not used in power plant)

• Average spent carbon generation is 200 MT/ year

• Rs. 15000 x 200 MT = Total Rs. 30,00,000

• Incineration cost saving = Rs. 30,00,000

Fuel cost saving 1 MT of spent carbon is equivalent to 1.4 MT of coal as per

Calorific Value.

• Average spent carbon generation is 200 MT/ year

• Fuel cost saving = Rs. 9,24,000

• 200 MT x 1.4 = 280 MT of coal

• Cost of coal = Rs. 3300/ MT

Total saving 280 MT x 3300 = Rs. 9,24,000

Total savings per year = Rs. 30,00,000 + Rs. 9,24,000 = Rs. 39,24,000

34

Involvement of Top Management by putting forward ”Energy” as one of

the elements contributing towards achieving “World Class refinery” tag.

Dedicating energy task force team formed comprising of experts from

various cross functional roles to promote energy initiatives.

Promoting culture for continuous EnCon idea generation/ out of the box/

innovation quest for energy optimization at each unit level.

APC module implemented to optimize the operation in various unit.

Indirect losses on slop processing, yield loss and product quality giveaway

minimized by diligent Operation.

Minimizing power consumption through optimum selection/loading of

drives.

Monitoring all Fluid coupling drives & variable frequency drives.

Distillation temp, pressure adjustments with changing feed rates /qualities

BEST PRACTICES IMPLEMENTED ON ENERGY FRONT

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Close monitoring of high energy intensive equipment performance, e.g.

Furnaces & Boilers, rotating equipments distillation columns.

Carrying out a comprehensive Hydrocarbon Loss Audit.

Online monitoring of all Flare valves to minimize flare loss.

Third party audit (Energy, F&L, Electrical) in Refinery.

Prepared Energy mapping of each unit.

Developed energy Metrics of each unit.

Low grade heat utilization.

Outsourcing steam traps management to minimize steam losses.

Improved accuracy of loss estimation.


36


37

Encouragement/ Information

Idea Generation –MOC Portal

GRM/Energy/

HSEF

ENCON Team

RLT

INFORMATION: Energy Intensive

equipment Specific consumption

Steam, power, fuel Flaring & Loss Pump/Turbine Efficiency Critical operating

parameters & deviation ENCOURAGEMENT : GEM Dec month

celebration Energy Awareness

sessions Quiz Leaflet circulation

Daily report & monitoring Target Setting for Fuel,

Power, Steam Legal compliance ISO 50001 compliance Brain storming sessions.

World Class Energy Team Monthly performance

presentation

EnCON REPORT

39

Date 25-Jul-17 26-Jul-17 Report Date 25-Jul-17

CDU-1 Daily Energy Monitoring

Utility consumption CDU-1 Throughput (MTPD)

UOM Remarks Design 51400.00

Power consumed MW / Hr 19.43 Actual (As per MIS) 51002.32

Fuel consumedSlop processing

(m3/hr)% Capacity Utilisation

99.23

FO MTPD 411.35 11.02 Crude Throughput (MTPD)

FG MTPD 128.00 CDU-1 (As per MIS) 51002.32FO LHV Kcal/Kg 9608.79 CDU-2 (As per MIS) 7124.63

FG LHV Kcal/Kg 10738.56Total Crude Processed

58126.95

Wt fraction FO 76%

Steam UOM Import / Export (-) Internal

GenerationTotal Steam

ConsumptionRemarks

L P steam Kg/Hr 39818.87 18343.21 58162.08M P steam Kg/Hr -644.40 40762.90 40118.50H P steam Kg/Hr NA NA NA

BFW As per B/L FTFor LPS

generationFor MPS generation

Blowdown/Diff / desuperheater

M3/hr 0.00 24.91 41.05 -65.96Instrument Air Nm3/hr 604.38

40

Heater MonitoringParameters (Target) UOM CDU heater A CDU heater B VDU heater A VDU heater BDesign Thermal efficiency % 89.50 89.50 89.50 89.50Net Thermal efficiency % 87.14 86.12 89.1 89.41Stack loss Kcal/Kg of fuel 1027.85 1132.81 845.05 828.24Total Fuel flow FO (KG/hr) 6985.54 11795.73 2056.46 1472.45

FG (NM3/Hr) 2211.25 2042.42 856.20 856.20Heater Inlet Flow m3/hr 1411.99 1420.18 805.47 705.88FD fan Air flow Kg/Hr 79730.64 96149.70 72133.25 65077.80Draft MMWC -5.48 -4.31 -7.05 -3.91O2 in flue gas (Target-3.5) % 1.87 1.67 2.46 2.14CIT Deg C 270.02 270.02 359.57 359.57COT Deg C 367.00 367.00 410.25 410.99Combustion Air Temp Deg C 229.57 309.02 212.25 190.89Flue gas Temp (APH I/L) Deg C 467.01 483.46 334.34 333.18ID fan Suction temp Deg C 170.68 170.31 177.36 191.80Stack Temperature(Target-180/185/187/180)

Deg C 237.85 273.14 183.4 175.55

Avg Stack damper opening % 43 45 -4 26Specific Consumption

Power KWH / DayKWH /

MT Unit FeedKWH /

MT Crude T'put% SRFT Power /

MT Unit feed% SRFT Power/ MT Crude T'put

Target 8.9Actual 466224 9.141 8.021 0.07861% 0.06898%

Fuel (FO+FG) MTPDMT fuel/

MT Unit feedMT fuel/

MT Crude T'put% SRFT Fuel / MT Unit feed

% SRFT fuel / MT Crude T'put

Target 1.00 0.87Actual 539.35 0.011 0.009 1.044% 0.916%

Steam Kg/hrKg Steam/

MT Unit feedKg Steam/

MT Crude T'put% SRFT/

MT Unit feed% SRFT/

MT Crude T'putLPS Target

LP 58162.08 27.37 24.01 0.183% 0.161%MPS Target 17.00

MP 40118.50 18.88 16.56 0.138% 0.121%HPS Target

HP NA NA NA

Unit Energy % SRFT/ MT unit Feed

1.444% Unit Energy % SRFT / MT Crude T'put 1.267%

41

Arpankumar PanchalManager, Process(M) [email protected]

Nitinkumar ChokshiGM, Lead Encon & Process(M) [email protected]

essar oil limited - greenbusinesscentre.comgreenbusinesscentre.com... · essar oil facilities at...

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