Certificate of Merit Refinery

INDIAN OIL CORPORATION LIMITED

Haldia Refinery, Purba Medinipur (West Bengal)

Unit Profile

Haldia Refinery is the fourth in the chain of ten (10) operating Refineries of Indian
Oil Corporation Ltd and commissioned in January 1975. It is also one of the two
refineries of Indian Oil Group Companies producing Lube Oil Base Stocks (LOBS).
The Refinery is spread over an area of about 500 acres and comprises different
blocks of processing units - Fuel Oil Block (FOB), Lube Oil Block (LOB), DHDS
Block, OHCU block, Oil Movement & Storage (OM&S) and Utility sections for
generating and distributing steam, power, air and other utilities.

Growth:

Initially installed with a 2.5 MMTPA crude processing capacity with designed LOBS
production capacity of 200,000 MTPA. The capacity of the refinery have been
augmented to 7.5 MMTPA subsequently through revamp of Crude distillation unit
in the year 2009-10.

Since commissioning of the Paradip-Haldia Crude oil Pipeline (PHCPL) in Jan’09,

the refinery started receiving crude oil from Paradip port and receiving of crude by
oil Tankers through oil jetties has come down resulting in optimization of

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transportation costs of crude oil. The Refinery has facilities for storage of crude
oil and finished products produced by the refinery.

Energy Consumption: 2014-15

Form-A of the annual report for the Yr 2014-15 is reproduced below:

1 Electricity
(a) Purchased
Unit (‘000 kWh) 22964
(b) Own Generation
(i) Through Dual Fuel (HSD/
Natural Gas Generators)
Unit (‘000 kWh) 380846
(ii) Through Steam Turbine/
Generators Unit (‘000 kWh) 75452
(iii) Through Solar
Unit (‘000 kWh) 24
(c) Electricity Consumed
(a + b) (‘000 kWh)
2 Coal
3 Liquid Fuel (LSHS/FO/Naphtha)
Qty (MTs) 510834
4 Others / Internal Fuel
a) Internal Fuel
i) Fuel Gas
Unit (MTs) 90825
ii) LDO / HSD
Unit (MTs) 250
ii) Coke
Unit (MTs) 43007
Consumption per MT of Production :
i) Actual Production (‘000 MTs) 6821
ii) Consumption per MT of Product
- Electricity (kWh/MT) 70.26
- Liquid Fuel (MT/MT) [F.O./Naphtha/HSD] 0.066
- Fuel Gas/ Coke (MT/MT) 0.019

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Energy Conservation Achievements 2014-15

 Group-1 LOBS was stopped thus idling unit SDU since Apr’14,resulting in
improvement 30-35 MT of MP steam and 3-3.5 MWH of power

Saving achieved: 22672 SRFT/Yr.

 Reduction of SWS Re-Bolier LP Steam in Apr’14 by reducing the SWS operating

pressure from 1.0 to 0.50 Kg/cm2(g) resulting in reduction of 4 MT/Hr of LP
Steam and 20 KW power saving by stopping 1 circulating pump

Saving achieved: 1868 SRFT/Yr.

 Antifoulant dosing in CDU-I since Apr’14

Saving achieved: 670 SRFT/Yr.

 Reduction in spillback to 3% from 30% opening in DHDS MUG since Aug’14

resulting in power savings of 500 kWh.

Saving achieved: 880 SRFT/Yr.

 Stoppage of De-ethaniser of CDU-II since Apr’14 resulting in improvement of

LPG make-up by 0.4 MT/hr, reduction of Fuel Gas by equivalent amount and
Savings of Re-Boiler Duty of about 0.1 Gcal/hr

Saving achieved: 80 SRFT/Yr

 9 nos of Helical Heat Exchanger installed in CDU-I for pre-heat improvement

by 14°C (ie from 260 to 274 °C) in Oct’14

Saving achieved: 3500 SRFT/Yr

 Heavy Naphtha withdrawal ex PF of CDU-I resumed from Oct’14 thus reducing

load in furnaces

Saving achieved: 1280 SRFT/Yr

 Steam trap management of 7000 nos. of offsite steam traps started since
May’14

Saving achieved: 2037 SRFT/Yr

 Condensate recovery system installed and commissioned in 700 tank farm

in Oct’14 resulting in condensate recovery of about 3 MT/hr

Saving achieved: Rs 18 lakhs/Yr

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 ATF flushing oil recovery from TWL started since Sep’14

Saving achieved: 1747 SRFT/Yr

 Back wash facility provided to Flare Gas Recovery System (FGRS) coolers in
Apr’14 for improved Flare gas recovery.

 Regular PM of Flare Gas Recovery System and KHDS recompression

compressor started since May’14 to reduce flaring.

 Dead band increment from +/- 2 % to +/-3% in Split Range control valves
connected to Flare in FOB and LOB unit completed in May’14-June’14 resulting
in reduction in flare loss.

 CRU PSA absorbant replacement done in Dec’14 resulting in improvement of

H2 recovery by 594 Kg/hr ( 498 Kg/hr to 1092 Kg/hr)

Saving achieved: 2682 SRFT/Yr

 Uprating of GT-2 completed in Sep’14 and that of GT-3 completed in Feb’15

resulting in Heat Rate improvement

Saving achieved: 1700 SRFT/Yr

 RFCCU MAB Turbine Vacuum Improvement done in Apr’14 from 0.69 to 0.89
Kg/cm2 by identification & Rectification of Air leak resulting in saving of MP
steam by 3.5 MT/hr.

Saving achieved: 3200 SRFT/Yr

 Replacement of Supplementary Naphtha firing in HRSG-2&3 with Fuel gas

since Apr’14 resulting in saving of Naphtha and there by reduction of flare
loss

Saving achieved: 14000 SRFT/Yr

 Provision of Fuel Gas burning in Boilers for reduction of Flare loss since June’14
there by reduction of flare loss

Saving achieved: 650 SRFT/Yr

 100 nos of 70W sodium vapor street light was replaced with 48 W LED street
light in Refinery Township during 2014-15.

 2000 nos of 32 W T-5 tube light was replaced with 18 W LED tube light in
Refinery during 2014-15.

 50 KW of solar energy implemented on top of DHDS control room and

commissioned in Aug’14

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Energy Conservation Commitment, Policy and Setup

Haldia Refinery has always accorded top-most priority for energy conservation
and a dedicated Energy Conservation and Technical Audit Cell ( ENCON/TA ) has
been set up in the Refinery right from the time of commissioning of the Refinery.
This cell is headed by a Chief Technical Services Manager (CTSM) and includes
Energy Manager and experienced chemical engineer for monitoring, reviewing the
refinery operations and implementing energy conservation measures in the refinery.

The engineers from ENCON/TA cell monitor the energy consumption on daily
basis and take necessary corrective action on regular basis to improve the energy
index of the Refinery. Energy performance of the refinery is also reviewed at
different level of the organization including Director Refinery & chairman of the
company. In the MOU of Indian Oil Corporation Limited with the Government of
India, Energy index of the Refinery including Specific Energy Consumption (MBN)
are also key parameters.

Regular survey is carried out with regard to steam leaks, insulation effectiveness,
product loading / dispatch operations, energy balance etc. to identify potential
areas of improvement. These improved areas have been converted into monthly
target for implementation by the different departments in the Refinery.

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