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Eeis - Final Report (Rev.1) - Iocl HR
Eeis - Final Report (Rev.1) - Iocl HR
COMPREHENSIVE STUDY
FOR
ENERGY & PERFORMANCE IMPROVEMENT
SUBMITTED TO:
&
IOCL- HALDIA CENTRE FOR HIGH
REFINERY TECHNOLOGY
PREPARED BY:
APRIL- 2018
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT
A981-0000-03-41-SR-011
IOCL- HALDIA REFINERY Rev. 1
FINAL REPORT
COMPREHENSIVE STUDY
FOR
ENERGY & PERFORMANCE IMPROVEMENT
SUBMITTED TO
IOCL HALDIA
&
CENTRE FOR HIGH TECHNOLOGY
PREPARED BY
ENGINEERS INDIA LIMITED
NEW DELHI
ACKNOWLEDGEMENT
Engineers India Ltd. takes this opportunity to thank Centre for High Technology
(CHT) and IOCL-Haldia Management, their EnCon Group / Technical Services &
Operations Departments for extending their extensive co-operation and logistic
support to EIL team during the execution of the Energy & Performance Improvement
Study.
Collection of data and operating characteristics of the unit is a major and most time
consuming exercise. The co-operation and efforts of refinery personnel in providing
the requisite data for the study as well as their valuable suggestions are highly
appreciated. EIL also thanks IOCL-Haldia personnel who have contributed directly or
indirectly in the compilation & analysis of the data and made available the relevant
documents / records as and when required by EIL team.
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CONTENTS
SECTION DESCRIPTION
EXECUTIVE SUMMARY…………………………………………………..01
1.0 INTRODUCTION……………………………………………………………19
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EXECUTIVE SUMMARY
I. Background:
Climate change by global warming has made it obligatory to all the Nations to
reduce the carbon emission for saving the Earth and Environment. Energy
consumption by industries, in which refineries are part of, contributes
substantially to carbon emissions. Further, Energy constitutes a major operating
cost and hence reduction in fuel & loss offers great potential and incentive to
improve unit performance as well as overall refinery profitability, thereby,
reducing harmful emissions.
Bureau of Energy Efficiency (BEE) along with Centre for High Technology (CHT
has developed a mechanism of PAT cycles, to reduce the MBN (Million British
Thermal Unit per Thousand barrels per Energy Factor) of refineries along with
other high energy consuming industries. The targeted reduction in MBN is
calculated in terms of Metric Ton of Oil Equivalent (MTOE) corresponding to
refinery’s performance in FY 2015-16 and should be achieved by FY 2021-22
as per PAT-II Cycle.
CHT intended to have comprehensive study for all PSU refineries carried out in
two parts – Part-A & Part-B. Under Part-A study (current study), the major
objectives include identification of energy saving areas, performance evaluation
(of process units, Utilities, off-sites & major energy guzzler equipment) and
developing Energy Saving Schemes (ESS) covering Quick wins, projects with
minor investment (short-term) and projects with major investment (medium-
term), order-of-magnitude cost with a straight-line payback period. Under Part-
B, refineries will identify energy saving schemes selected from Part-A
recommendations for further evaluation and feasibility. The Part-A study has
been awarded to EIL
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As a part of the study, EIL conducted a KOM to finalize the List of Units, Base
case month (January, 2016) for operating data, utility cost, Fuel Oil Equivalent
(FOE) of utilities, and other considerations. IOCL-HR also provided a list of Base
line ENCON schemes, for reference, which are not required to be pursued by
EIL under Part-A.
Following sequential stages have been adopted by EIL to carry out Part-A
energy study:
i. Data collection
ii. Data screening, analysis and reconciliation
iii. Technical interaction & refinery site visit
iv. Study and identification of potential EnCon areas
v. Development of Interim EnCon schemes and submission to Refinery
vi. Engineering evaluation and costing
vii. Submission of Draft Report
viii. Submission of Final Report.
Crude distillation and vacuum distillation are the primary units producing
direct fuels feedstock to downstream secondary units. These are the major
energy consuming units in the refinery. The energy efficiency improvement
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areas have been identified and recommended in CDU’s & VDU’s are as
follows:
Note:
1. Option-1 includes Replacement/Up-gradation of existing CDU-1 & 2, VDU-
1 & 2 with new, integrated, state of the art, efficient CDU/VDU and other
quick wins pertaining to CDU-1, 2 and VDU-1, 2 (preferred by IOCL HR)
2. Option-2 includes all other EnCon schemes except the Replacement of
CDUs/VDUs and replacement of CDUs heaters. Savings under Option-2:
10, 540 MTOE/Yr.
b. MS Block
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OHCU is processing Heavy gas oil (HGO) and vacuum gas oil (VGO) from
VDU. FCCU is processing VGO from VDUs. In this unit, the major heat
losses are thorough heater & boiler flue gases and also through condensing
turbine drive of WGC. The following are the energy efficiency improvement
areas:
d. Treating Units
Treating Units in IOCL-HR consists of DHDS and KHDS to meet the diesel
and kerosene product specifications as per BS-IV norms. It is observed that
there is potential for improving the inter and intra unit heat integration, by hot
feed maximisation. The recommended schemes is:
e. Sulphur Block
In Sulphur block, energy losses are mainly due to amine supply system to
DHDT & OHCU, and cooling & reheating of streams in TGTU. The energy
saving schemes that are proposed in this block include:
Increasing the inlet temperature of rich amine feed to amine regeneration
units
Installation of plate type heat exchangers to increase the sour water
temperature.
The total Energy Savings: 3,200 MTOE/Yr.
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f. Hydrogen Management
From the study and analysis of the overall refinery, it has been observed that
major energy loss, in this section, are due to improper condensate recovery
/ steam network management and HRSG / boiler blow downs. Accordingly,
based on overall heat and mass balance, loss of condensate and steam from
the system and energy potential in terms of steam to de-aerator are
quantified. Recommended schemes are:
It is observed that the entire area is traced with steam and due to inherent
inefficiencies in steam network, high amounts of steam/condensate loss is
observed. Under this section following schemes are recommended:
Electrical tracing of offsite area
Employing latest technology like fan less cooling tower in place of
conventional induced draft cooling towers
Flare Gas Recovery
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a. Heat Integration
This is an energy study area in which the potential of inter unit and intra unit heat
integration is explored. Under inter unit heat integration, it is observed that most
of the heat potential in the streams is lost through the air-coolers/ trim coolers
during their routing to storage or due to the existing configuration / operating
philosophy. So, wherever possible, emphasis is given to increase the preheat
temperature of feed to the unit / equipment. Under this category, various schemes
like feed preheat improvement in CDU, NHT CRU, KHDS and heat recovery from
product rundown of VDU-I are studied and recommended.
Under intra unit heat integration, emphasis is given to identify areas in which heat
potential in streams / system is not utilized due to the inherent unit configuration.
The potential schemes recommended in this area include installation of hot
separator for heat recovery from stripper bottoms in OHCU.
This energy study area mainly focuses on the effective utilization of low level heat
available with different streams in the refinery viz. unit rundowns, flue gases from
boilers/heaters and boiler blow-downs. It is observed that these streams have
significant heat potential which is currently disposed off to atmosphere directly (in
case of flue gases) or lost through air coolers / trim coolers.
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The schemes recommended under this category are heat recovery from boiler’s
& HRSG’s blow down and Low End Heat Recovery from Exhaust Gas of GT-
HRSGs & flue gas of furnaces.
This is an important area of energy saving explored during the study. Under this,
thrust is given to implement the new technologies and also to replace the existing
inefficient system with a new and efficient systems. Refinery is losing substantial
energy through hydrogen rich fuel gas to flare, loss due to condensation of steam
and inefficient condensate recovery systems.
As a part of this, new energy saving schemes like use of electrical tracing / heating
in place of steam tracing / heating, plate type heat exchangers in SWS/ARU, flare
gas recovery, and fan less cooling towers in place of conventional induced draft
cooling towers are also recommended.
The schemes that are recommended, as part of this area of energy study are
recovery of hydrogen from refinery off gases, change of condensing turbine / back
pressure drives to motor drives in FCC, reduction of VDU-I column top pressure,
rationalization of air compressors.
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Any energy saving scheme, if implemented in the refinery will most of the time
affect the steam network and / or power network. Therefore, these facilities need
to be optimized. In the current scenario, a complete steam and power network
balance has been carried out for the scenario in which all the energy schemes
accepted by IOCL-HR are assumed as implemented. The energy saving
measures identified in this area are
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The total Energy Saving Schemes (ESS) along with the MTOE/Yr. saving and
payback are listed in the Table 2. In other form, the savings equal to
approximately INR 376 Crores / Yr. which results in a saving of ~ INR 502 /Ton
of Crude processed.
MTOE Payback
S. No Unit ENCON Scheme
Savings period
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4 years 4
27 CPP Rationalisation of Boiler operations 10000
months
2 year 2
31 Refinery Flare Gas Recovery 3800
months
Note 1: This scheme is alternative to the scheme No.13 titled “Replacement / Up-
gradation of existing CDUVDU with a brand new state-of-the-art efficient unit” and the
energy savings are not included in total MTOEs.
(**) Schemes are part of revamp / implemented during study / require detailed study /
Quick-wins/strategic-investment
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2 year 2
31 Refinery Flare Gas Recovery 3800
months
Low End Heat Recovery From Exhaust Gas of 2 years 2
32 Refinery 800
CIDW and DHDS furnace months
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Note 1: This scheme is alternative to the scheme No.13 titled “Replacement / Up-
gradation of existing CDUVDU with a brand new state-of-the-art efficient unit” and the
energy savings are not included in total MTOEs.
(**) Schemes are part of revamp / implemented during study / require detailed study /
Quick-wins/strategic-investment
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IOCL-HALDIA RFINERY
SECTION 1.0
INTRODUCTION
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1.0 INTRODUCTION
Petroleum refinery while being a vital source of fuel and energy to various end
users, consume a part of the crude for its captive use as fuel and power. In
addition, processing losses often accounted as “loss” add to the normal
operating cost. Refinery configuration and complexity, process technology
employed as well as its product slate & specifications are the major contributing
factors towards energy consumption. However, inter-unit heat integration, use
of energy efficient equipment and addition of energy saving devices/ schemes
etc. can reduce fuel consumption and loss leading to the improved performance
of a refinery.
Depending upon the various factors outlined above, typical fuel and oil losses
vary from 7 to 10% of the crude processed (expressed as fuel oil equivalent)
based on their complexity. The fuel & loss figures tend to increase as more and
more secondary processing units are added either for meeting stringent fuel
specifications or for upgrading bottom of the barrel for converting heavier
fractions to more & more light & middle distillates for improving profit margins.
Though, the Indian refineries have long understood the importance of energy
optimization & effective management as cornerstone for sustenance, the energy
study’s outcome often suggests that there are still considerable number of
potential areas that can be taken-up by the refinery for further reduction in
energy consumption.
Climate change by global warming has made obligatory to the Nations to reduce
the carbon emission to save the earth and environment. Industries are the major
source of carbon emission and accordingly BEE developed a mechanism for
monitoring and control of the carbon emission in the industry by introducing PAT
Cycle system. Under PAT Cycle-I very high energy intensive and polluting
industries were included. Whereas, under PAT Cycle-II, some more industries
and Petroleum refinery sector are added.
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Bureau of Energy Efficiency (BEE) along with Centre for High Technology
(CHT) has set the refinery specific MBN (Million British Thermal Unit per
Thousand barrels per Energy Factor) reduction targets. On the basis of MBN,
energy savings target in Metric Ton of Oil Equivalent (MTOE) for medium term
(2021-22) have been worked out considering the refinery’s performance
corresponding to FY 2015-16. For IOCL-HR, same is finalized as 96,000
MTOE/Yr. which includes short term (2018-19) target of 19,000 MTOE/Yr.
Accordingly, CHT intended to have comprehensive study for all PSU refineries
carried out by EIL to reduce the specific energy consumption in both short term
and Medium term in line with final proposal dated 23rd Sept 2016.
IOCL HR entrusted EIL for carrying out the Comprehensive study on Energy
and Performance improvement to meet the targets set by BEE / CHT vide Work
Order No. 24950205 dated 12th Dec 2016. The study includes the Process
Plants and Utilities (Steam and Power) for its Refinery.
The various milestones in the projects include Kick off meeting with IOCL-HR
on 12th Dec 2016, subsequently Refinery Specific Data Formats were submitted
to IOCL HR; Technical interaction & refinery site visit was made; ENCON
schemes were developed & interim report on Energy Saving Schemes (ESS)
were submitted to refinery on 30th May 2017. Interaction and approval of
ENCON schemes & Finalization of ENCON schemes were done thereafter.
Draft Report was submitted to refinery on 13.11.2017. Comments on draft report
from HR was received in 3 stages during Dec.17 and Jan.18 and response to
all consolidated comments on draft report was sent to HR on 7th Feb. 2018.
This Study Report covers various sections - Section-2 mentions the objective of
the study. Section 3 & 4 cover the Basis of Study and Methodology Adopted,
respectively. Section 5 discusses the Energy / Performance study & analysis of
various schemes under different units. Each sub-section describes the energy
schemes of the respective units which include the recommended configuration,
energy savings and order of magnitude cost. Section-6 summarises the energy
savings employing unique areas explored. Also included in the report are
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IOCL-HALDIA RFINERY
Haldia Refinery, the 4th Refinery of Indian Oil was commissioned in January
1975. It is situated 136 km down-stream of Kolkata in the district of Purba
Medinipur, West Bengal, near the confluence of river Hooghly and Haldia.
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 of four blocks viz. Fuel Oil Block (FOB), Lube Oil Block (LOB),
DHDS and OHCU Blocks besides Oil Movement & storage (OM&S) and Utilities
block.
Initially installed with a crude processing capacity of 2.5 MMTPA, capacity of the
Refinery was increased to 2.75 MMTPA through de-bottlenecking in 1989-90,
and 3.75 MMTPA in 1997 with the installation/commissioning of the 2nd CDU of
1.0 MMTPA capacity. The Refinery has subsequently been augmented to its
present capacity of 7.5 MMTPA.
Haldia Refinery is currently the only coastal Refinery of the Corporation (till such
time Paradip Refinery is commissioned) and one of the two Indian Oil Group
companies producing LOBS, apart from being the sole producer of Jute Batching
Oil.
A Catalytic Dewaxing Unit (CDWU) was installed and commissioned in the year
2003 for production of high quality LOBS meeting the API Grade-II standard of
LOBS. Haldia Refinery also produces eco-friendly Bitumen emulsion and Micro-
Crystalline Wax. Refinery has recently introduced new products viz. API Gr-III
LOBS and 380 cSt Bunker Furnace oil. Typical block diagram of IOCL Haldia
Refinery highlighting various units, feed & product routing is as shown in figure
1.1
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Rev. 1
IOCL-HALDIA RFINERY
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SECTION 2.0
OBJECTIVE OF THE STUDY
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Above factors also result in, lower profitability and adverse impact on the
environment.
35893
45, 981
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Thereby, meeting the energy saving target as well as increasing the refinery
profitability.
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SECTION 3.0
BASIS OF THE STUDY
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The basis for energy efficiency improvement study (EEIS) has been finalized
with IOCL-HR subsequent to the award of job after a detailed discussion
during kick-off meeting on 12th Dec 2016. Following basis has been agreed &
adopted for the study:
The entire list of the units that are in operation were finalized for the study.
Subsequently, the units which are less energy intensive or not intended to be
operated in future (shut down) were excluded from the final list of units that
have been considered for the study.
Refinery sector has been covered under PAT (Perform, Achieve and Trade)
Cycle-II starting from 1st April, 2016. Refinery specific energy saving target is
decided based on performance data of the refinery in the year 2015-16 data.
IOCL-Haldia has decided the base case month as January, 2016 for operating
data evaluation based on the optimum throughput and running of maximum
number of process units in the refinery.
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Different fuels vary in quality and calorific value. For uniformity, the
Standard Reference Fuel (SRF), with net calorific value of 10,000 kcal/kg,
has been used for all energy number calculations.
The Fuel Oil Equivalent (FOE) used for various utilities are as follows.
1 Ton SRF = 14.0 Tons of Steam
= 5500 KWH of Power
= 20,000 m3 of circulating Cooling Water
In order to establish the energy consumption for various process units, the
following approach has been adopted:
Energy study has been carried out considering operating data suitably
prorated for design loads
PGTR reports and DCS graphics have also been considered as per
requirement during evaluation/calculation to have a consistent data
wherever required
The energy estimation for each unit has been done based on the normal
operation of the unit without taking into account start-ups/shut downs,
intermittent utility requirements, emergencies, operational upsets etc.
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SECTION 4.0
METHODOLOGY ADOPTED
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As per the final techno-commercial proposal document agreed with CHT and
refineries, the energy study was planned to be carried out in two parts - Part A
and Part B. Identification of the potential areas and developing the EnCon
schemes are covered under Part-A.
Present study pertains to part A, and the following sequential stages have been
adopted to carry out the techno-economic feasibility analysis of different energy
improvement schemes:
i. Data collection
ii. Data screening, analysis and reconciliation
iii. Technical interaction & refinery site visit
iv. Study and identification of potential EnCon areas
v. Development of Interim EnCon schemes and submission to Refinery
vi. Engineering evaluation and costing
vii. Submission of Draft Report
viii. Submission of Final Report.
Data collection is the most important and crucial phase of the project. It is not
only the most time consuming activity but also demands significant information
about the unit’s present status as well as its trend. The success of any Energy
Efficiency Improvement Study greatly depends on the accuracy of the data.
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Therefore, it is important to have the right and authentic data to achieve the
desired results.
To handle the huge data/documents required for the study covering various
units, offsites and utilities, a systematic methodology has been adopted as
described below:
i. Initially, FTP server was created for uploading & downloading of the
data/documents.
ii. During project kick-off meeting, EIL explained the type of data/documents
required for the study, document handling procedure in FTP server and also
explained sample format for filling the operating data.
iii. Refinery has uploaded required basic documents (PFD, stream summary
etc.) for preparation of Unit/Equipment specific data formats for obtaining
operating data.
iv. EIL prepared Refinery Specific Data Formats (RSDF) and uploaded on FTP
server. EIL has also facilitated the refinery by providing audio/video
guidelines to fill the operating data in RSDF.
v. IOCL-HR uploaded filled-in RSDF and additional supporting Data/
documents on FTP server
The next phase of the study is data screening, analysing and reconciliation of
filled-in data based on design data, past trend, in-house technical data bank and
design tools. Steps followed are mentioned as below:
o All the data and information collected have been analysed thoroughly to
check their consistency, completeness and correctness.
o In case of units which were not running at full capacity/had some operational
upsets during the base case month; operating data near to base case month
was considered for such units.
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
o Test run data/DCS graphics have also been used where-ever deemed fit.
Based upon the information consolidated as per above steps, a consistent set
of data adequate for the study was compiled.
o Energy team consisting of various domain experts from EIL visited IOCL-HR
for technical discussion on the filled-in operating data with EnCon team,
personnel of technical department and to get feedback from plant operating
personnel of various units.
o Brain storming session along with EnCon, technical services and unit
operational Heads/managers for better understanding of the unit operating
performance and constraints, if any.
o Preliminary site observations of various units and offsites along with the
refinery personnel were carried out. Collection of balance data/documents
was done from technical services/EnCon team that was required further
based on the outcome of these interaction.
The key to the study is to identify various energy conservation schemes along
with their energy saving potential , a brief site feasibility and costing based on
the operating/design data. This is further explained as below:
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
o Design documents, filled-in operating data, test run reports and DCS screen
shots, in-house data bank and design tools have been used for developing
the schemes. In house data base was used only in absence of data or
inconsistency.
o Various Software tools/ technologies available with EIL have been used for
developing and evaluating the schemes.
o An interim EnCon Saving Scheme (ESS) format having various details like
existing arrangement, observations, recommended arrangement,
envisaged savings has been shared with IOCL-HR for their comments/
discussions and also to obtain in-principal approval on prima-facie
technically viable schemes for further evaluation.
o IOCL-HR team visited EIL office for technical discussion on the proposed
schemes followed by EIL’s site visit for further clarification/broad site
feasibility checks of approved schemes.
o Based on study of remaining areas, additional EnCon schemes were
identified and submitted to IOCL-HR for discussion/approval in addition to
already submitted interim schemes.
Final interaction was held subsequently for detailed discussion and acceptance
of all these recommended schemes during the visit of EIL team to IOCL-HR.
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34
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
EnCon schemes that are finally approved by IOCL-HR have been further
evaluated and broad based feasibility has been done. Further, order-of-
magnitude cost and straight-line payback period has been estimated for all the
schemes.
***********************
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35
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
SECTION 5.0
ENERGY & PERFORMANCE ANALYSIS
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
CDU, VDU and associated heat recovery systems from pump-around are the
prominent part of primary operating units in a refinery as they provide many
direct distillate products as well as feedstock to secondary process units like
once-through Hydro-Cracker Unit, Fluid Catalytic Cracking (FCC), etc. IOCL HR
has two stand-alone CDUs (CDU-I & CDU-II). The reduced crude oil (RCO) from
CDU-I and CDU-II are routed to VDU-II and VDU-I respectively.
5.1.1 Crude Distillation Unit - I (CDU I)/Vacuum Distillation Unit – II (VDU II)
CDU-I was originally designed by Technip, France and it was revamped for a
throughput of 3.5 MMTPA in 1996. At present, unit is operating at 100%
throughput and feed to the unit is heavy crude. The RCO of CDU-I is routed to
VDU-II for further fractionation.
a. Existing Configuration
At present, 580 kg/h and 180 kg/h of stripping steam is being used in
LGO stripper (11-C-02B) & HGO stripper (11-C-02C), respectively to
maintain the flash points of LGO and HGO products.
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
c. Recommended Scheme
Use of stripping steam to LGO stripper & HGO stripper can be stopped
completely under BS-VI operation. The stripping steam may be reduced
gradually while maintaining products specification.
The reduction in the stripping steam will also reduce the sour water
generation from the unit, thereby reducing the energy (LP Steam)
required for heating in sour water strippers.
d. Energy Savings
Remark: It is recommended that the use of stripping steam to LGO stripper &
HGO stripper to be stopped completely for BS-VI scenario.
a. Existing Configuration
11-F-01 is a balanced draft, dual fired crude heater, has design absorbed
duty of 35.0 MMkcal/h & provided with outboard CAPH and SAPH.
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
c. Recommended Scheme
In order to optimize the excess air, recommendations are as given below:
d. Energy Savings
There is a scope of energy saving by optimizing the excess air and to
bring down O2 content in the flue gas from 8.13% to 3.0% (near to
design). With this, nearly 1480 MTOE/Yr. saving is possible.
e. Implementation Aspects
Following aspects are required to be taken care during implementation:
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
Two nozzles of the size 3'' to 4’’ across the length of the fire box on
the upper side of the radiant box for installation of Source and
receiver of laser beam. Also ensuring unobstructed optical path
between source and receiver.
Change the faulty components of the burner during shutdown.
a. Existing Configuration
11-F-01 is a balanced draft, dual fired crude heater, has design absorbed
duty of 35.0 MMkcal/h & provided with outboard CAPH and SAPH.
c. Recommended Scheme
In order to optimize the stack temperature, recommendations are as
given below:
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40
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
Replace CAPH.
Replace stack dampers with control/TSO type dampers.
Replace combustion air dampers by control/TSO type dampers.
Cleaning of convection section
Inspect and replace faulty burners/burner parts
Inspect and repair/replace faulty soot blowers.
d. Energy Savings
e. Implementation Aspects
Following aspects are required to be taken care during implementation:
Replace the APH during shutdown
Augmentation of convection section, replacement of stack damper
and combustion air bypass damper job to be planned during shorter
shutdown
Convection section tubes cleaning to be taken up during heater shut
down
Soot blowers to be repaired as per maintenance schedule
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41
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
Remarks: IOCL-HR has taken the appropriate action during TSRD in Dec 2017.
a. Existing Configuration
82-F-01 is a balanced draft vacuum heater, has design absorbed duty of
34.35 MMkcal/hr.
c. Recommended Scheme
In order to optimize the excess air, recommendations are as given below:
d. Energy Savings
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
e. Implementation Aspects
Following aspects are required to be taken care during implementation:
Two nozzles of the size 3'' to 4’’ across the length of the fire box on
the upper side of the radiant box for installation of Source and
receiver of laser beam. Also ensuring unobstructed optical path
between source and receiver.
Change the faulty components of the burner during shutdown.
5.1.2 Crude Distillation Unit - II (CDU II) and Vacuum Distillation Unit I (VDU I)
a. Existing Configuration
At present, 385 kg/h and 300 kg/h of stripping steam is being used in
LGO stripper (16-C-02B) & HGO stripper (16-C-02C), respectively to
maintain the flash points of LGO and HGO products.
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
c. Recommended Scheme
Use of stripping steam to LGO stripper & HGO stripper can be stopped
completely under BS-VI operation. The stripping steam may be reduced
gradually while maintaining products specification.
The reduction in the stripping steam will also reduce the sour water
generation from the unit, thereby reducing the energy (LP Steam)
required for heating in sour water strippers.
d. Energy Savings
Remark: It is recommended that the use of stripping steam to LGO stripper &
HGO stripper to be stopped completely for BS-VI scenario.
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
a. Existing Configuration
c. Recommended Scheme
d. Energy Savings
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45
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
a. Existing Configuration
CDU-II consists mainly of preheat exchanger train, Atmospheric
column, Naphtha stabilizer, Naphtha Splitter. The Preheat Train has
three parts:
Preheat train I – up to desalter
Preheat train II – desalted crude to Prefractionator column
Preheat train III – pretopped crude to crude furnace inlet
c. Recommended Scheme
Considering optimum approach temperature in exchangers, and
maximum heat recovery of products (lower temperature at the cooler
inlet) it is recommended to achieve the design preheat temperature of
274 °C for this crude in CDU-II. Prima facie, increase in preheat
temperature will be ~ 25 °C, which reduces the furnace duty by ~ 8
MMkcal/hr. However, a detailed pinch analysis is to be carried out for
holistic preheat optimization study.
d. Energy Savings
The energy savings w.r.to preheat improvement in CDU-II is estimated
to be ~ 6000 MTOE/Yr.
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46
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
a. Existing Configuration
A recirculating tempered water circuit is provided in the unit to avoid over
cooling of products SR & IO. Tempered water at 60 oC is pumped to SR
Tempered Water Cooler (E-124 A/B/C) & IO Tempered Water Cooler (E-
125 A/B/C). The heated tempered water at 80 oC is then returned back
to tempered water drum after cooling to 60 oC in Tempered Water Air
Coolers. (Refer Figure No.-5.1.1)
Existing Arrangement:
T 190 T 120
SR In SR Out
E-124 A/B/C
T 230 T 85
IO In IO Out
E-125 A/B
c. Recommended scheme
Based on EIL’s recent design practices, it is recommended to recover the
heat from these products, which are currently being cooled in Tempered
water circuit in VDU I preheat network. Recoverable heat from SR and
IO streams is around 1.127 MMkcal/hr & 1.65 MMkcal/hr respectively.
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47
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
Recommeded Arrangement:
VDU I Preheat
Network
T 190 T 120
SR In SR Out
E-124 A/B/C
T 230 T 85
IO In IO Out
E-125 A/B
d. Energy Savings
The energy saving potential w.r.to the recommended ENCON scheme
is estimated to be ~ 1300 MTOE/Yr.
This scheme is considered as Medium term measure.
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48
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
a. Existing Configuration
16-F-01 and 16-F-101 are balanced draft, dual fired crude heaters,
having design absorbed duty of 28.8 MMkcal/h and 16.1 MMkcal/h,
respectively, provided with outboard APH system.
c. Recommended Scheme
In order to optimize the excess air, recommendations are as given below:
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49
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
Inspect and change the faulty components of the burner / fine tune
the burners.
Computational Fluid Dynamics (CFD) study for combustion air
distribution duct.
d. Energy Savings
There is a scope of energy saving by optimizing the excess air and to
bring down O2 content in the flue gas to 3.0% (near to design). With this,
nearly 470 MTOE/Yr saving is possible.
e. Implementation Aspects
Following aspects are required to be taken care during implementation:
Two nozzles of the size 3'' to 4’’ across the length of the fire box on
the upper side of the radiant box for installation of Source and
receiver of laser beam. Also ensuring unobstructed optical path
between source and receiver.
Change the faulty components of the burner during shutdown.
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50
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
a. Existing Configuration
16-F-01 is a balanced draft, dual fired crude heater, has design absorbed
duty of 28.8 MMkcal/h & provided with outboard CAPH and SAPH
system.
b. Observations & Analysis
Based on operating data, following observations are made and analysed:
c. Recommended Scheme
In order to optimize the stack temperature, recommendations are as
given below:
Replace CAPH.
Replace stack dampers with control/TSO type dampers.
Replace combustion air dampers by control/TSO type dampers.
Cleaning of convection section
Inspect and replace faulty burners/burner parts
Inspect and repair/replace faulty soot blowers.
d. Energy Savings
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51
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
e. Implementation Aspects
Following aspects are required to be taken care during implementation:
Replace the APH during shutdown
Augmentation of convection section, replacement of stack damper
and combustion air bypass damper job to be planned during shorter
shutdown
Convection section tubes cleaning to be taken up during heater shut
down
Soot blowers to be repaired as per maintenance schedule
a. Existing Configuration
31-F-01 and 31-F-02 are balanced draft vacuum heaters, having design
absorbed duty of 22.41 MMkcal/hr and 11.0 MMkcal/hr, respectively.
52
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
c. Recommended Scheme
In order to optimize the excess air, recommendations are as given below:
d. Energy Savings
There is a scope of energy saving by optimizing the excess air and to
bring down O2 content in the flue gas to 3.0% (near to design). With this,
nearly 190 MTOE/Yr saving is possible.
e. Implementation Aspects
Following aspects are required to be taken care during implementation:
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53
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
Two nozzles of the size 3'' to 4’’ across the length of the fire box on
the upper side of the radiant box for installation of Source and
receiver of laser beam. Also ensuring unobstructed optical path
between source and receiver.
Change the faulty components of the burner during shutdown.
a. Existing Configuration
31-F-01 and 31-F-02 are balanced draft vacuum heaters, having design
absorbed duty of 22.41 MMkcal/hr and 11.0 MMkcal/hr, respectively.
Stack temperature are high (31-F-01: 229 0C and 31-F-02: 195 0C).
31-F-01, APH having heat transfer problem.
Convection section cleaning is required
Critical dampers are not working properly.
31-F-02, Convection section/APH cleaning is required
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54
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
c. Recommended Scheme
In order to optimize the stack temperature, recommendations are as
given below:
31-F-01:
a. Cleaning/Replacement of CAPH
b. Replace stack dampers with control/TSO type dampers.
c. Replace combustion air dampers by control/TSO type
dampers.
d. Cleaning of convection section
e. Inspect and replace faulty burners/burner parts
f. Inspect and repair/replace faulty soot blowers.
31-F-02:
a. Convection section/APH cleaning is required
d. Energy Savings
e. Implementation Aspects
Following aspects are required to be taken care during implementation:
Cleaning of APH during shutdown
replacement of stack damper and combustion air bypass damper job
to be planned during shorter shutdown
Convection section tubes cleaning to be taken up during heater shut
down
Soot blowers to be repaired as per maintenance schedule
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55
COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
Estimated cost of
New Stack Damper (2Nos) : 24 Lakhs
New Combustion air bypass Dampers (2Nos) : 20 Lakhs
Savings from this EnCon scheme : 165 Lakhs/Yr
Straight-line payback : < 4 Months
a. Existing Configuration
CDU-I was originally designed by Technip, France and it was revamped
for a throughput of 3.5 MMTPA in 1996. At present, unit is operating at
100% throughput and feed to the unit is heavy crude. The RCO of CDU-
I is routed to VDU-II for further fractionation.
CDU-II was originally designed by Technip, France and it was revamped
for a throughput of 4.1 MMTPA in 1996. At present, unit is operating at
100% throughput and feed to the unit is mix of light and heavy crude. The
RCO of CDU-II is routed to VDU-I for further fractionation.
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
Calculated Energy
6.44 5.97
Consumption, TPH
Design Energy
Consumed 1.51 2.39
(FOE / MT of crude in %)
Calculated Energy
7.77 3.36
Consumption, TPH
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
4.00 VDU-I
3.00 VDU-II
2.00
1.00
0.00
POWER FUEL STEAM WATER
c. Recommended Arrangement
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT A981-0000-03-41-SR-011
2 1.75
FOE (%)
1.5
0.5
0
New CDU/VDU
CDUs & VDUs
From above data, it is clear that existing CDUs &VDUs are consuming
2.48 % of FOE to process combined flow of 950 TPH feed. In contrast,
high efficient new CDU/VDU is consuming around 1.75 % FOE for
processing the same throughput and also keeping the same product
pattern.
d. Energy Saved
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59
COMPREHENSIVE STUDY FOR
ENERGY & PERFORMANCE IMPROVEMENT Document No.
A981-0000-03-41-SR-011
IOCL HALDIA REFINERY
Rev. 1
Energy study and analysis of Naphtha Hydrotreating Unit (NHT) and Catalytic
Reforming Unit (CRU) of MS Block is explained below:
NHT-CRU was built by M/S Technip using a process licensed jointly by Indian
Institute of Petroleum, India & Institute Francais du Pet role, France for
processing 196 TMT of Naphtha. A major revamp was carried out, with
process licensed by M/S Axens France, to increase capacity, enhance product
quality. The complete replacement of catalysts with UOP catalysts was carried
out to meet Euro-IV specifications in year 2012. CRU Block consists of
Naphtha Hydrotreating Unit (NHDT) and Catalytic Reformer Unit (CRU).
Heavy SR naphtha and Heavy FCC gasoline are taken as feed in the
revamped NHDT unit. Heavy SR naphtha comes from the bottom of naphtha
splitter (unit-85). Feed naphtha is reacted with hydrogen in the presence of a
Nickel- Molybdenum (Ni-Mo) catalyst in a reactor at elevated temperature and
pressure. Sulphur and Nitrogen in feed naphtha are reduced to as low as 0.5
wt ppm and 0.1 wt ppm respectively in this unit. After the reaction process, the
naphtha is stripped to remove light ends, impurities like Hydrogen Sulphide
and water (Moisture).
The hydro treated naphtha from the stripper bottom is routed to the Reformer
unit as a hot feed. A capacity of Catalytic Reforming unit is 0.216 MMTPA.
Purpose of Catalytic Reformer Unit is to improve octane number of
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COMPREHENSIVE STUDY FOR
ENERGY & PERFORMANCE IMPROVEMENT Document No.
A981-0000-03-41-SR-011
IOCL HALDIA REFINERY
Rev. 1
Stabilization section
a. Existing Arrangement
61
COMPREHENSIVE STUDY FOR
ENERGY & PERFORMANCE IMPROVEMENT Document No.
A981-0000-03-41-SR-011
IOCL HALDIA REFINERY
Rev. 1
Existing Arrangement
2nd 1st
Hydrotreating Hydrotreating
Reactor Reactor
21-R-201 21-R-01
Naphtha
from NSU T = 40 Heavy FCC
Gasoline Feed
Surge Drum
21-B-201 T 305
T 331
T 44 T 233
Reactor
T 40 Feed/Effluent Reactor Feed
T 139 Exchangers Heater
21-E-01 A/B/C 21-F-01
Heavy FCC Gasoline
Feed Pumps Heavy SR Q = 4.94 Q = 1.37
(21-P-201 A/B) Naphtha from
blanketed
storage
62
COMPREHENSIVE STUDY FOR
ENERGY & PERFORMANCE IMPROVEMENT Document No.
A981-0000-03-41-SR-011
IOCL HALDIA REFINERY
Rev. 1
Recommended Arrangement
2nd 1st
Hydrotreating Hydrotreating
Reactor Reactor
21-R-201 21-R-01
Naphtha
from NSU T = 40 Heavy FCC
Gasoline Feed
Surge Drum T 116
21-B-201 T 305
T 331
T 44 T 70 T 268.8
New Reactor
T 40 Exchangers Feed/Effluent Reactor Feed
21-E-XXX Exchangers Heater
21-E-01 A/B/C 21-F-01
Heavy FCC Gasoline Q = 0.678
Feed Pumps Heavy SR Q = 5.20 Q = 0.69
(21-P-201 A/B) Naphtha from
blanketed 129
T
storage
Additional
Reactor
Reactor Feed/Effluent Exchangers Energy
Case Feed
Recovered
Heater
(MMkcal/h)
Inlet Temp. Outlet Duty Duty
(oC) Temp. (oC) (MMkcal/h) (MMkcal/h)
Existing 44 233 4.94 1.37 ---
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COMPREHENSIVE STUDY FOR
ENERGY & PERFORMANCE IMPROVEMENT Document No.
A981-0000-03-41-SR-011
IOCL HALDIA REFINERY
Rev. 1
d. Energy Savings
Existing Revised
Parameters Unit
Conditions Conditions
Reactor Feed/Effluent Exchangers
(21-E-01 A/B/C)
o
Feed I/L Temperature C 44 70
o
Feed O/L Temperature C 233 268.8
o
Reactor Effluent I/L Temperature C 331 331
o
Reactor Effluent O/L Temperature C 139 129
Duty MMkcal/h 4.94 5.20
Reactor Feed Heater (21-F-01)
o
Feed I/L Temperature C 233 268.8
o
Feed O/L Temperature C 305 305
Duty MMkcal/h 1.37 0.69
Reduction in Heater duty MMkcal/h 0.68
New Proposed Exchanger
o
Feed I/L Temperature C --- 44
o
Feed O/L Temperature C --- 77
Duty MMkcal/h --- 0.678
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COMPREHENSIVE STUDY FOR
ENERGY & PERFORMANCE IMPROVEMENT Document No.
A981-0000-03-41-SR-011
IOCL HALDIA REFINERY
Rev. 1
e. Implementation aspects
Preliminary site feasibility is done, and it is found that the
recommended scheme is prima facie feasible. Following
implementation aspects to be taken care:
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT
A981-0000-03-41-SR-011
IOCL -HALDIA REFINERY Rev. 1
The function of this unit is to catalytically crack mixtures of vacuum tower gas
oils, vacuum tower bottoms, de-asphalted gas oils, slack wax gas oils and
furfural/MMP extracts. These feed stocks crack into low boiling, high value
products, primarily LCO, C3-C4 LPG and Gasoline.
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT
A981-0000-03-41-SR-011
IOCL -HALDIA REFINERY Rev. 1
a. Existing Configuration:
In the existing configuration, Wet Gas Compressor (WGC) in FCCU is
driven by condensing turbine which is consuming MP steam of 14
Kg/cm2g Pressure & temperature is around 300 OC.
c. Recommended Arrangement:
It is recommended that the existing Turbine drive is to be replaced with
motor having shaft horse power (SHP) of 1.5 MWH with efficiency of
motor greater than 96 %.
d. Energy Savings:
The Energy saving by implementing this scheme is as shown below:
Total Steam consumed : 11.5 TPH
Total Power Required by Motor : 1.5 MWH
Steam MTOE : 6571 MTOE/Yr
Power MTOE : 2150 MTOE/Yr
The calculated energy saving by Conversion of turbine driven to motor is
~ 4400 MTOE /Yr.
e. Implementation aspects:
To implement this scheme, motor and driven equipment shafts are
connected and synchronized with minimum downtime.
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a. Existing Configuration:
In the existing configuration, Main Air Blower (MAB) in FCCU is driven by
condensing turbine which is consuming MP steam of 14 Kg/cm2g
Pressure & temperature is around 300 OC.
c. Recommended Arrangement:
It is recommended that the existing Turbine drive is to be replaced with
motor having shaft horse power (SHP) of 4.2 MWH with efficiency of
motor greater than 96 % along with Gear Box and VFD.
d. Energy Savings:
The Energy saving by implementing this scheme is as shown below:
Total Steam consumed : 32.5 TPH
Total Power Required by Motor : 4.2 MWH
Steam MTOE : 18571 MTOE/Yr
Power MTOE : 6077 MTOE/Yr
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ENERGY & PERFORMANCE IMPROVEMENT
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e. Implementation aspects:
To implement this scheme, motor and driven equipment shafts are
connected through Gear Box and to control the speed, VFD should also
be installed and synchronized with motor with minimum downtime
Remarks: Considering the energy saving potential /steam network reduction, this
scheme could be considered suitably under long term plan w.r.t major revamp,
modernization/expansion of the unit. Same may be pursued subsequently for detailing
with the post BS VI steam & power balance scenario.
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT
A981-0000-03-41-SR-011
IOCL -HALDIA REFINERY Rev. 1
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a. Existing Configuration:
Reactor effluent from reactor outlet, enters the last feed/ effluent exchanger (91-
E-02) at 390◦C and exits at 296◦C. It further exchanges its heat in heat
exchangers and gets cooled in air cooler (91-AC-01) up to 55◦C and enters into
cold high pressure separator where the hydrocarbon liquid is separated from its
vapours. Diesel from the low pressure flash drum bottom exits at 55◦C, which
gets preheated from first stripper feed/reactor effluent exchanger (91-E-03) and
91-E-04, up to 269 ◦C). The schematic of the existing arrangement is shown in
figure 5.3.1
To Stripper
226 oC 269 oC
R/E
91-AC-01
390 0C 296 oC 245 oC 196 oC 155 oC 55oC To RGC H2 Rec.
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ENERGY & PERFORMANCE IMPROVEMENT
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IOCL -HALDIA REFINERY Rev. 1
reactor effluent exchangers (E-03 & E-04) to raise the temperature up to 269◦C.
Due to this stripper feed is being cooled initially and reheated to desired
temperature levels leading to loss of energy through air coolers.
c. Recommended Scheme:
It is recommended to install a hot separator and a hot flash drum after last
feed/effluent exchanger and MP steam generator at 260◦C. By installing the hot
separator at high temperature as mentioned above, the outlet temperature of
the vapours from hot high pressure separator will be around 260◦C which will
heat the feed and recycle gas from 200◦C to 226◦C in existing exchanger (91-E-
01) along with one additional exchanger. The net liquid from cold flash drum
will be heated with hot separator vapours up to 150◦C with existing exchanger
91-E-03. Due to this, excess heat of 9.73 MMkcal/h will be available in reactor
effluent to generate nearly 16 tons of MP steam. The schematic of the
recommended scheme is shown in Figure-5.3.2.
260 oC
HP Hot Separator
AC-XX
0.7 MMkcal/h
91-E-04
BYPASS
Hot flash drum
New HPRT
To stripper @ 260 0C
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ENERGY & PERFORMANCE IMPROVEMENT
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d. Energy Savings:
Presently the reactor effluent exchanges heat with stripper feed which will be by
passed after hot separator installation and MP steam will be generated from
excess heat in reactor effluent. Thus steam generated is worked out to be 16
tons/h and equivalent savings of MTOE will be around ~9300 MTOE. The
energy saving calculations are provided in Table 5.3.1.
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e. Implementation Aspects:
The scheme involves installation of a new high pressure and low pressure hot
separators, additional exchanger for recycle gas heating from hot high pressure
separator vapours, a new MP Steam generator after last feed/ effluent
exchanger and (91-E-02) and new PRT at hot separator bottom.
Remarks: Considering the energy saving potential /steam network reduction, this
scheme could be considered suitably under long term plan w.r.t major revamp,
modernization/expansion of the unit. Same may be pursued subsequently for
detailing.
a. Existing Configuration
91-F-01 and 91-F-02 are balanced draft heaters, having design absorbed
duty of 12.04 MMkcal/hr and 28.15 MMkcal/hr, respectively.
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d. Energy Savings
There is a scope of energy saving by optimizing the excess air and to
bring down O2 content in the flue gas to 3.0% (near to design). With this,
nearly 510 MTOE/Yr saving is possible.
e. Implementation Aspects
Following aspects are required to be taken care during implementation:
Two nozzles of the size 3'' to 4’’ across the length of the fire box on
the upper side of the radiant box for installation of Source and
receiver of laser beam. Also ensuring unobstructed optical path
between source and receiver.
Change the faulty components of the burner during shutdown.
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COMPREHENSIVE STUDY FOR Document No.
ENERGY & PERFORMANCE IMPROVEMENT
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IOCL -HALDIA REFINERY Rev. 1
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1. Hot feed to KHDS unit at 700C Directly from B/L & Increasing the Pre-heat
by 150C thus reducing the Furnace Duty
a) Existing Configuration:
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Cold feed at 40o C coming from B/L is passed through the preheat
exchangers (23-E-02 A/B/C/D), where temperature is raised upto 230 o
C, and finally to reactor through feed charge heater. The schematic of
the existing configuration is shown in figure. 5.4.1
2890C
KHDS Reactors
23-R-01
289 0C
245 0C
2300C
40 0C
FeedPump
23-P-01
TO R/E air Cooler
128 0C
c) Recommended Scheme:
Instead of cooling the CDU rundown up to 40o C by air coolers, it can
be directly routed to KHDS unit at 60o C thus increasing the preheat
temperature by 3-40C and reducing the furnace duty. The schematic of
recommended scheme is shown in Figure 5.4.2
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2890C
KHDS Reactors
23-R-01
289 0C
245 0C
2340C
60 0C
23-E-02B 23-E-02A DHDT Charge Heater
23-E-02 C/D
23-F-01
3.75MMkcal/h
FeedPump
23-P-01
TO R/E air Cooler
1370C
d) Energy Saved:
Based on operating conditions, furnace inlet is at 234o C and outlet is
289o C and the corresponding duty is around 4 MMkcal/h. By taking hot
feed at 600C from upstream CDU (around 80%), the furnace inlet temp
can be increased by 2-30C to 2370C leading to reduction in furnace duty
by 0.2 MMkcal/h. The corresponding energy saved is around 150
MTOEs.
e) Implementation Aspects:
Feed filter, feed coalescer and feed pumps (23-P-01 A/B) are found to
be adequate for the recommended ENCON scheme.
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COMPREHENSIVE STUDY FOR
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ENERGY & PERFORMANCE IMPROVEMENT
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The Sulphur block comprises of Sulphur Recovery Unit (SRU-28 & 83: 60 TPD
each and SRU-95: 80 TPD each), common Tail Gas Treating Unit (for SRU-28, 83
& 95 unit), Amine Regeneration Unit (ARU-26:139 m3/h and ARU-93: 453 m3/h)
and Sour Water Stripping Unit (SWS-29: 75 m3/h and SWS-94: 25 m3/h).
SRU is designed to recover the sulphur from Acid gases from ARU and Sour gases
from the SWSU. SRU has Thermal section, Catalytic sections, Liquid sulphur
handling section and Incineration section. The tail gas leaving SRUs is further
processed in TGTU.
Tail gas from SRUs is routed to TGTU to increase the sulphur recovery to 99.9%.
It consists of Hydrogenation and Amine sections. In Hydrogenation section all
sulphur species are converted to H2S and H2S is absorbed in Amine. Regeneration
of amine produces H2S, which is routed back to front end of SRU.
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a. Existing Configuration :
In ARU (93), currently shell and tube module is in operation as Lean-Rich
Amine heat exchanger. The rich amine flow and temperature to column is
280 m3/h and 103oC, respectively.
c. Recommended Arrangement:
It is recommended to bypass shell and tube heat exchanger with new plate
type heat exchanger. So that, LP steam supply to reboiler’s is reduced.
d. Energy Savings:
In Unit 93: Duty saved in reboiler = 280*1000*7/10^6 = 1.96 MMkcal/h
MTOEs saved = (8000*1.96*10^6)/10^7 = 1568
Total energy savings corresponding to this scheme is ~ 1500 MTOE/Yr.
e. Implementation Aspects:
Foot print of new plate type heat exchanger (L x W x H), in m:
ARU-93: 1.5 x 1.5 x 3.3
Detailed study is required before implementation.
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Sour water from various units in the refinery is collected in a sour water surge
drum. The collected sour water is pumped to sour water stripper of single stage
stripper via feed/bottom exchanger. Separated sour gases from the single stage
stripper is sent to sulphur recovery unit for recovering elemental sulphur and
stripped water from sour water stripper is sent to unit as make-up for wash water
and partly to ETP for disposal. LP steam is used to provide the heat in the reboiler
in the single stage sour water stripper.
a. Existing configuration:
In SWSU (29 & 94), currently shell and tube module is in operation as Feed-
bottom heat exchanger. The sour water temperature to column is 90oC and
87oC for SWSU-29 and SWSU-94, respectively.
c. Recommended Arrangement:
It is recommended to replace shell and tube heat exchanger with plate type
heat exchanger. So that, LP steam supply to reboiler’s is reduced.
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d. Energy Savings:
Duty saved in reboilers:
In Unit 29 = 75*1000*(110-90)/10^6 = 1.5 MMkcal/h
In Unit 94 = 30*1000*(110-87)/10^6 = 0.69 MMkcal/h
Total duty saved = 2.19 MMkcal/h
MTOEs saved = (8000*2.19*10^6)/10^7 = 1752
Total energy savings corresponding to this scheme is ~ 1700 MTOE/Yr.
e. Implementation Aspects:
Foot print of new plate type heat exchanger (L x W x H), in m:
SWS-29:1.5 x 1.5 x 2.0
SWS-94:1.2 X 1.2 X 2.0
Detailed study is required before implementation.
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The design and operation of refinery hydrogen distribution system usually begins
with a consideration of number of sinks and available sources of hydrogen at site.
The hydrogen used in the refinery can have different origins.
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Hydrogen Purifiers
i) PSA in Hydrogen Generation units (HGU)
ii) PSA for CRU off-gases
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COMPREHENSIVE STUDY FOR
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Rev. 1
IOCL HALDIA REFINERY
LP off-gas
DHDT
LP off-gas
Under Shutdown
HGU-1
DHDS
HP & LP off-gas
HGU-2 OHCU
LP off-gas
MQU-ISOM
LP off-gas
CRU CRU PSA
MSQ- PRIME
G
LP off-gas
NHDT
LP off-gas
CRU
CDWU
KHDS
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It is understood that, the hydrogen requirement in all consumer units are satisfied
by HGU, CRU off-gas. The off-gas from CRU unit is routed to CRU PSA to produce
hydrogen of 99.99% purity.
The LP off-gases from units like DHDT, DHDS, OHCU, MSQ (ISOM), MSQ
(PRIME-G), KHDS, NHDT, CDWU are being routed to fuel gas header.
The compositions of the hydrogen rich off-gases from various units routed to fuel
gas header are tabulated below in Table. 5.6.1
Flow, Hydrogen
Units H2 Rich Off-gases
TPH Purity (mol%)
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c. Recommended scheme
For recovering hydrogen from these streams, a scheme is being proposed. The
presence of H2S content in NHT off gas is to be removed before being routed to
PSA system. In the proposed scheme, the off-gases from the DHDT, DHDS,
OHCU, MSQ (ISOM), MSQ (PRIME-G), KHDS, NHDT, CDWU are routed to new
PSA system.
The off gases are available at a pressure of 5 kg/cm2, which has to be compressed
to a pressure of 30 kg/cm2 to process in PSA. Even though, there is one PSA
(CRU-PSA) available in IOCL HR for processing the off gases, new PSA
considered for this scheme as the existing PSAs are being operated at the design
throughput. The recommended hydrogen scheme is given in Fig. 5.6.2
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COMPREHENSIVE STUDY FOR
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The recommended scheme for hydrogen recovery is shown in the figure -5.6.2 below:
Offgas
Compressor
Inter Stage
Cooler
XX-E-01
Offgas
Compressor
2nd Stage
KOD
XX-V-02
12 kg/cm2
H2
30 kg/cm2 g Product
PSA
5 kg/cm2 g Unit
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d. Energy Saved
Based on the recommended scheme, the hydrogen recovered from the H2 rich off-
gases is around 720 kg/hr. The net energy savings is calculated as
Net Energy Savings = Hydrocarbon savings − Alternate fuel gas − Operating cost
e. Implementation aspects
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f. Economic Analysis
The capacity of the recommended hydrogen recovery scheme for IOCL HR is 5.8
KTPA. New HGU unit of similar capacity range will be a very small unit to be
considered in the refinery. Therefore, capital cost for both units cannot be directly
compared. The Plant & Machinery cost of the recommended scheme is estimated
~ Rs. 105 Crores.
While, there is no revenue generation from HGU, from the recommended scheme,
net revenue generation from hydrogen recovery is about Rs. 87 Crores per annum,
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Rev. 1
IOCL – HALDIA REFINERY
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a. Existing configuration :
Detailed mass balance across the refinery, considering the variables such
as make up DM water to Deaerators, stripped water to ETP, steam to HGU,
blow down, atomizing steam and unrecovered steam/condensate etc.is
carried out. It has been observed that there is additional condensate
recovery potential available and it is recommended for recovering the same.
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The total Make up DM water to various Deaerators in the entire refinery complex
is as shown in Table 5.7.1.
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Overall DM water balance for steam generation refinery is carried out and is as
shown in Figure 5.7.2. Steam consumed in stripping, Blow down, as feed in
hydrogen reformer, atomizing steam for fuel oil, soot blowing etc. cannot be
recovered and thus could not be returned to Deaerators. To account for this
loss, equivalent DM water has to be make-up in Deaerators which sums up to
~191 TPH. But actual DM water Make up to Deaerators is ~290 TPH. Thus an
additional ~99 TPH of DM water is to be Make-up because of loss in either
Steam or condensate form. Out of the total Condensate /steam lost,
approximately 20% of ~99 TPH could be live steam loss either through stream
traps/pin holes/ valves/flanges etc. and remaining 80 % could be in the form of
condensate and is as presented in Figure 5.7.3
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DM water makeup to
Deaerators:
290 TPH
Refinery Block
Steam generation Steam Loss (~20 TPH)
(548 TPH) Condensate Loss (~79 TPH)
191 TPH
The steam generation and consumption is across the entire refinery complex
and is managed via steam Headers at various pressure levels. Thus the
Steam/condensate loss could be across the refinery. A complete survey of
steam system is to be carried out to find out physical losses and to be
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Refinery steam and power network is many times expanded in stages and
invariably results in a complex system of multiple steam and power
generators. These utilities generators may use different fuels and have
different thermal efficiency and hence different production costs. The
strategies which can be adopted for operating the total utilities system in an
optimum manner for a particular process load, product requirements and
within the existing hardware constraints are many and there exist opportunity
to optimize steam and power production for fuel / cost minimization. To
optimize such a complex system with large variables, linear programming
approach can be used as an effective tool.
d. Energy Savings:
e. Implementation Aspects:
The Steam and condensate recovery starts from better steam trap
management. A proper Condensate recovery system adds strength for a
better steam and condensate recovery as there is a huge potential. Most
importantly, consumption of steam is to be optimized by adopting various
ENCON schemes as a holistic approach.
Various commercially proven steam accessories like Advanced Steam traps,
Pre- fold manifold, Pre-insulated tubing and flash steam recovery including
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This scheme involves a detailed study across the entire refinery. After steam
trap management and accessing actual steam generation and consumption
of various equipment’s by reliable instrumentation, an overall steam balance
has to be again carried out to bridge the gap between actual generation and
consumption. Accordingly condensate recovery system has to be designed
for recovering condensate back to Deaerators which then accounts for actual
order-of-magnitude cost.
Remark: IOCL HR has taken the action in FO and Bitumen area. Further,
scope exists.
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may help to bring it down further by adjusting the existing tubes with a
low pressure drop design. Heat Recovery envisaged from all the GTs is
~16.6 MMkcal/hr. The values are as represented in Figure 5.7.5.
c. Recommendation:
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which is earlier being heated with other process streams or any other
fluid that can ultimately run a Vapour Absorption Machine (VAM).
The heat recovered can be utilised in generating power in ORC, but the
efficiency of power generation may not justify the implementation of this
scheme.
d. Energy Savings:
The actual total energy recovery potential at the back end of HRSG is to
the tune of 16.6 MMkcal/h. However based on efficiency of VAM only
10.82 MMkcal/h is the potential by recovering entire heat in to DM water.
The VAM machine is envisaged to generate around 3575 TR which is
approximated to ~8652 MTOE/yr. This Chilling load can help in reduction
of power required in chillers for AHUs if this chilled water generated is
used in place of existing chillers or augmenting power in Gas Turbines if
it is used to cool the inlet air of Gas Turbines.
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e. Implementation Aspects:
The scheme involves creating two new facilities mainly the Extra heat
surface area at the back end of HRSG and an altogether new Vapour
Absorption Machine (VAM) module if envisaged. In a detailed study,
existing heat transfer are in HRSG shell may be replaced with low
pressure drop high heat transfer finned tubes to act upon reduction of
additional pressure drop created by installing heat recovery system at
back end.
VAM is generally modular in nature and can be easily accommodated in
the CPP area. Extra space could be created by replacing existing CPP
cooling tower with the fan less cooling tower which is proposed as a
separate scheme.
This is a medium term scheme as it involves handling critical equipment
like Gas Turbines as additional surface has to be created in Back end.
The VAM is a modular one and so can be installed easily but needs
creating additional space near the CPP area.
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c. Recommended Arrangement:
To recover Flash LP steam from this hot Blow-down, Flash vessels can
be installed for all Boilers & HRSGs separately to generate LP steam of
3 Kg/cm2g and 2.5 Kg/cm2g respectively for direct consumption in
Deaerators as shown in Figure 5.7.6
d. Energy Savings:
By installing flash vessel, ~ 0.67 TPH of LP steam from boiler blow down
and 0.7 TPH of LP steam from HRSG blow down is generated. Also the
remaining heat in the blow down can be extracted by placing an
exchanger as shown in the figure 5.7.6. The total savings which is
equivalent to 1,200 MTOE /Yr.
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e. Implementation Aspects:
To recover Flash LP steam and additional heat recovery to DM water
from this hot Blow-down, Flash vessels followed by exchangers can be
installed for all Boilers & HRSGs separately.
It is a short term scheme to install flash vessel and an exchanger.
a. Existing Configuration:
Presently, around 65 TPH of MP steam that is required in the refinery is
generated via PRDS from HP steam.
c. Recommended Arrangement:
A Turbo generator can be installed to generate power from high pressure
HP steam that is presently being killed to MP steam in a PRDS. This
requires a parallel arrangement of Turbo generator to the existing PRDS
to meet the plant MP steam loads uninterruptedly as shown in Figure
5.7.7.
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d. Energy Savings:
e. Implementation Aspects:
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c. Recommended Arrangement:
The old inefficient Boilers i.e. boilers 1 & 3 can be replaced with New
highly energy efficiency state-of-the-art units. In case of Boiler-4,
replacing the APH may also be considered based on the detailed study.
Also, as the refinery is planning for replacing existing fuel from fuel oil to
Natural gas to all the Boilers, accordingly higher area in Air Pre-Heater in
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d. Energy Savings:
The Energy saved by replacing the Boilers is as shown in the Table 5.7.4
below.
Thus ~20,000 MTOE is saved by replacing the old boilers with brand new
highly efficient state-of-the-art Boilers. It has been mentioned that the
Boiler-1 and Boiler-3 are in operation for approximately 3-4 months in the
whole year. So savings are prorated and approximated to ~10,000 MTOE
e. Implementation Aspects:
The scheme involves replacing the old boilers with newer ones. It
requires detailed study of the available Boilers and then replacing them
with new ones. Some part of the old Boilers may be utilized in the new
one.
It is a medium term scheme to install a new Boilers.
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As per the Table 5.7.5, it can be noted that there is additional availability of 3
TPH, 84 TPH and 29 TPH of HP steam, MP steam and LP steam respectively
post implementation of these schemes. Through electrical balance, there is net
power requirement to the tune of 5.75 MW.
IOCL Haldia informed that due to implementation of various projects, the steam
as well as power demand is going to go up and thus proper steam balance has
to be carried out before going for installation of new steam/power generation
equipment.
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An Overall steam Power optimisation be taken altogether for running the GT,
Boiler and STG in an energy efficient manner through software tools like
EngCHP developed by EIL.
However, a complete steam balance has been done for a hypothetical scenario
in which all the energy schemes accepted by the Refinery are assumed as
implemented and is as shown in Table 5.7.6. The refinery Steam is balanced in
all the headers by balancing each header with best possible options.
HP MP LP
Sl.No Cases 60 kg/cm2g, 14 kg/cm2g, 2.5 kg/cm2g,
450oC 300oC 220oC
Base Case- Inputs
1 Steam Generation from UB 157.00
2 Steam generation from HRSGs 183.00
3 STG
4 Supply of Steam from HP to MP -148 96.00
5 PRDS
6 Supply of Steam from HP to MP -60 60.00
7 Turbines
Supply of Steam from MP to LP by Turbines
8 (BFW, CT & IFO pumps) -109.00 109.00
Calculations
Excess steam available in header wrt. Base case
9 due to Various schemes adopted 2.80 83.95 28.57
10 Options to balance steam headers
11 LP steam balance
Converting OHCU CT & DM water turbine driven
12 pump to motor (requires power of ~ 1.5 MW) 28.57 -28.57
13 Excess steam available in header 2.80 112.52 0.00
14 MP steam balance
15 Reducing steam from HP-MP PRDS 60.00 -60.00
Reducing steam from STG (Power generation
16 reduces by 3.3 MW) 52.51 -52.51
17 Excess steam available in header 115.31 0.00 0.00
18 HP steam balance
Reducing HP Steam generation from Utility
19 Boiler -115.31
20 Excess steam available in header 0.00 0.00 0.00
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**********
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Refinery consists of many utilities other than Steam and Power like IFO, Fuel
gas, Boiler feed water, DM water, cooling water, service water, drinking water,
Fire water, Plant/ Instrument air system, Nitrogen, Flare, Blow down, Flushing
oil and slop system etc. There is a provision to import LNG in IOCL Haldia is
being explored.
There are around 90 steam traced offsite tanks which are for storing feed and
products from various units and to maintain the temperature as heat is lost to
the atmosphere. The product lines that carry these hot products to and fro
between the units and tanks are also steam traced
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c. Recommended Arrangement:
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d. Energy Savings:
25714
12548
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e. Implementation Aspects:
The scheme involves replacing the existing steam tracing with electrical
tracing for both steam traced pipes and tanks. The tracing for Tanks and
pipes is different and thus requires different implementation philosophy.
Existing Steam traced pipes have steam tracer coil/s running along and
is insulated. Sometimes tracers are aided by heat transfer compounds
for better heat transfer between steam tracer and process pipe. For
implementing electrical tracing, the insulation over this pipes has to be
removed first and then electrical tracer Tape can be installed in a close
vicinity of pipe and bundled. The steam tracer is intact and need not be
removed as it can be used at times there is issue with electrical system.
Thus this gives flexibility to the refiner to operate both the systems as per
their convenience. But care is to be taken that both the systems should
not operate at the same time as it may damage the electrical system. The
insulation may be again utilized based on its condition or can be replaced
with a new and improved one to minimize heat loss.
Existing Steam traced Tanks have steam tracer coil/s running in to the
tanks just above the bottom of the tank providing the required heat and
the outer surface is well insulated to minimise the heat loss. For
implementing electrical tracing, the insulation over the Tanks has to be
removed first and then electrical tracer Tape can be installed in a close
vicinity of the tank. The steam tracer is intact and need not be removed
as it can be used at times there is issue with electrical system. Thus this
gives flexibility to the refiner to operate both the systems as per their
convenience. But care is to be taken that both the systems should not
operate at the same time as it may damage the electrical system. The
insulation may be again utilized based on its condition or can be replaced
with a new and improved vertical double-locking standing steam
insulation panel system to minimize heat loss and ease of installation.
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The power modules, thermostats, controller and panel stations etc. are
to be connected to existing power network of the refinery. The DCS
connectivity is of similar nature of data logging as already adopted in
refinery.
This scheme is a short term scheme as hot work can be done without
disturbing the running plant and it doesn’t warrant any down time of units
or offsite area. The scheme is easy to implement at site.
2. Replacing existing cooling towers with new fan less cooling tower
technology
a. Existing Configuration :
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Cooler water network is a heat rejection system in which already low grade
heat is wasted. Additional power is consumed by cooling tower fans in the
process of cooling the hot cooling water to desired temperature in cooling
towers which is again a waste of energy. As per the analysis of data of
existing cooling towers, they can be converted to fan-less cooling towers
without any impact on degree of cooling desired.
By replacing all the cooling towers in the refinery with this novel jet type fan-
less cooling towers in a phased manner, refinery can save power consumed
in the cooling tower fans. Details of cooling towers with their approximate fan
power consumption is tabulated in Table 5.8.1 below.
c. Recommendation:
It is recommended to replace existing cooling towers with jet induced fan
less cooling towers. This will help in reduction of power consumption in fans.
Also interconnection of cooling towers helps in reduction of power consumed
in Pumps as running many smaller pumps is less efficient to that of larger
ones. Interconnection between various cooling towers thus reduces
pumping loads during low temperature seasons when the cooling load
requirement comes down as pumps can operate at full loads instead of many
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pumps running at part load. The actual installed Fan-less cooling tower is as
shown in Figure 5.8.2.
d. Energy Savings:
By replacing above mentioned cooling towers with a Fan-less cooling
towers, the power requirement to the tune of ~ 2.1 MW can be reduced. Thus
~ 3000 MTOE can be saved per annum which can be further increased
considering power savings by consolidation and rationalization of small
cooling towers with larger one meeting combined capacity requirements.
e. Implementation Aspects:
The implementation of this scheme involves replacing existing cooling
towers with new jet type fan-less cooling tower. Consolidation and
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The fan-less cooling towers can be easily installed at site due to its modular
in nature. It can occupy the same foot print of existing cooling towers but
consume some extra elevation as it needs more volume compared to
traditional cooling towers.
It is a Short term scheme to replace existing cooling towers with new one
but overall cooling tower integration is a long term scheme as it needs
complete study of cooling water network.
In the Refinery complex, presently there are around 6 Air compressors under
continuous operation generating instrument air, plant air etc. Also there are
additional air compressors in the Nitrogen plant specifically to generate
Nitrogen required by the refinery. The total list of Air compressors that are
studied are as shown in Table 5.8.4. Also there are other compressors which
are in standby operation mode.
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c. Recommendation
As per the analysis, it has been observed that the Air compressors across
the Refinery in both TPS and DHDS units are running at part load and are
not performing well as they are running at lower capacities. So, it is thus
recommended to install a compressor of lower capacity and running others
at higher capacity at their best Efficiency point to meet the requirements or
to install VFD in the existing compressors.
The compressors 57-KM-02 and 74-K-101 are having more specific energy
consumption. So by replacing them with a low capacity one may help running
of other compressors at their best efficiency point. This may require installing
a new small air compressor of ~1200 nm3/h
Also it is recommended to go for Air leak survey before going for any actual
investment as the efficiency of the air network generally improves reducing
the compressor duty accordingly. How, ever IOCL HR mentioned that they
recently gone for Air leak survey.
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The data is only of air compressors for plant air and instrument air. Extending
the study considering Nitrogen compressors also can help in taking further
better decision as a common air network for service air and nitrogen plant
can help running a few compressors to meet the requirement at best
efficiency point and keeping others in standby mode.
d. Energy Saved:
By implementing this scheme of rationalization of air compressors, the power
consumption to the tune of ~ 0.56 MW can be reduced. Thus ~ 800 MTOE
is saved per annum which may be further increased by considering power
saved in compressors that are presently in service in nitrogen units and
taking up recommendation of air leak survey.
e. Implementation Aspects:
The total order of magnitude cost for implementing the scheme is based on
procuring a new compressor as below
New Centrifugal Air compressor with VFD: ~30 Lakhs
Energy Savings: ~196 Lakhs
The Payback come to be less than 6 months.
In the Refinery complex, presently there are two Flare gas recovery units of
liquid ring compressor type. The refinery still has flaring to the tune of ~4000
Tons per annum.
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c. Recommendation
It is recommended to install a new Flare gas recovery unit for additional flare
gas recovery along with existing ones. It is recommended to go for ejector
based flare gas recovery system with liquid water as motive fluid rising the
flare gas pressure to fuel gas header pressure as shown in figure 5.9.4.
Adding amine to water in proportion required can help bring any slipped H2S
content in the flare gas to the levels needed to add this flow to fuel gas
header. Else additional capacity is to be provided for cleaning the
compressed flare gas before sending it to fuel gas header.
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d. Energy Saved:
By implementing this scheme of flare gas recovery, ~ 0.5 TPH of flare gas is
recovered. The energy saving potential is as shown below.
Thus, ~ 3800 SRFT /yr is saved by implementing flare gas recover scheme.
However, it should be noted that the Hydrogen content is the flare is high,
so recovered flare gas can add up to Hydrogen recover scheme.
e. Implementation Aspects:
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pump, KOD setup along with a deep liquid seal setup as shown in figure
below. Also, any available pumps at the liquid flow of ~ 40 m3/h with a
discharge pressure of 80 barg can be used.
The total order of magnitude cost for implementing the scheme is based on
procuring a new flare gas recovery unit of the ejector type.
New Flare gas recovery unit: ~19 Crore
Energy Savings: ~9.22 Crore
The Payback come to be ~ 2 years and 2 months
Remarks: It has to be noted that refinery-wide study may minimize the flare
generation. As the refinery has 2 flare gas recovery units but flaring is still observed,
a detailed study is required to utilise the existing flare gas recovery compressors
before going for new ejector based system.
5. Low End Heat Recovery From Exhaust Gas of CIDW and DHDS furnace
a. Existing configuration :
In Existing configuration, there are three natural draft furnaces in CIDW
unit and one in DHDS unit of 2.85, 2.77, 5.2, 7.56 MMkcal/h fired duty
each respectively. The average stack temperature for these heaters are
590 oC, 450 oC, 280 oC, 405 oC respectively. Huge heat s lost through
there heaters to atmosphere.
b. Observations & Analysis:
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to bring it down further. Heat Recovery envisaged from all the furnaces
is ~1.11MMkcal/hr. The values are as shown in Table 5.8.5
Table 5.8.5 Low end heat recovery from furnace
Unit Heater fired duty, FG Operating Desired Duty TR
No MMKcal/h formed, stack temp, temp ex- recovered,
kg/h oC APH, oC MMkcal/h
CIDW 84-F-01 2.85 5703 590 250 0.38 125
CIDW 84-F-02 2.77 5533 450 250 0.22 71
CIDW 84-F-03 5.2 10400 280 250 0.06 20
DHDS 25-F-01 7.56 15120 405 250 0.46 151
c. Recommendation:
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d. Energy Savings:
The actual total energy recovery potential at the back end of furnaces is
to the tune of 1.53 MMkcal/h. However based on efficiency of VAM only
1.11 MMkcal/h can be recovered. This can be used to heat the DM water.
However the VAM machine is envisaged to generate around 366 TR
which is approximated to ~886 MTOE. This Chilling load can help in
reduction of power required in chillers for AHUs if this chilled water
generated is used in place of existing chillers.
e. Implementation Aspects:
The scheme involves creating two new facilities mainly the Extra heat
surface area at the back end of furnaces and an altogether new Vapour
Absorption Machine (VAM) module if envisaged
VAM is generally modular in nature and can be easily accommodated in
nearby area.
This is a medium term scheme as it involves handling critical equipment
like furnaces as additional surface has to be created in Back end. The
VAM is a modular one and so can be installed easily but needs creating
additional space near the CPP area.
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a) Existing Configuration:
Most of the high firing duty process heaters are dual fired and consumption
of total fuel Oil is around 96,000 Ton per annum.
Since fuel contains around 0.5 to 1.5 wt. % sulphur, there is a limiting
temperature for APH system design and corresponding thermal
efficiency achieved. For a dual fired system, efficiency on gas firing will
also be lower (similar to FO firing)
FO firing is also associated with a significant quantity of steam required
for atomisation.
FO firing also leads to soot deposition on extended surfaces in
convection section and APH resulting in lower heat transfer rate which
tends to lower the efficiency of the heaters. This is partly avoided by use
of soot blowing steam.
At times, dripping of the oil near burner/ coke formation in burner tip need
frequent attention for safe operation.
c) Recommended Scheme
In today’s scenario, gas firing is an attractive option for higher thermal
efficiency and stringent environmental requirement. Therefore, most of the
fired heaters are recommended for converting from dual firing to FG / NG.
Further, APH system can be designed / modified for 100% gas firing
corresponding to lower flue gas temperature (125 – 130 °C)
Switch over from F.O/dual firing to FG / NG firing will have following benefits:
Higher waste heat recovery from flue gas due to lower dew point.
Saving of steam used for FO atomization, Soot blowing
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d) Energy Savings
Total savings have been worked out as 5000 MTOE/Yr considering lower
stack temperature, less combustion air requirement, saving of atomization
steam and soot blowing steam.
This excludes savings from FO tanks heating / FO lines tracings/FO
pumping/ Maintenance cost of soot blower/F.O pumps/F.O tanks and lines
insulation.
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SECTION 6.0
SUMMARY OF RECOMMENDATIONS
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This is an energy study area in which the potential of inter unit and intra unit
heat integration is explored. Under inter unit heat integration, it is observed that
most of the heat potential in the streams is lost through the air-coolers/ trim
coolers during their routing to storage or due to the existing configuration /
operating philosophy. So, wherever possible, emphasis is given to increase the
preheat temperature of feed to the unit / equipment. Under this category, various
schemes like feed preheat improvement in CDU, NHT CRU, KHDS and heat
recovery from product rundown of VDU-I are studied and recommended.
Under intra unit heat integration, emphasis is given to identify areas in which
heat potential in streams / system is not utilized due to the inherent unit
configuration. The potential schemes recommended in this area include
installation of hot separator for heat recovery from stripper bottoms in OHCU
This energy study area mainly focuses on the effective utilization of low level
heat available with different streams in the refinery viz. unit rundowns, flue
gases from boilers/heaters and boiler blow-downs. It is observed that these
streams have significant heat potential which is currently disposed off to
atmosphere directly (in case of flue gases) or lost through air coolers / trim
coolers.
The schemes recommended under this category are heat recovery from boiler’s
& HRSG’s blow down and Low End Heat Recovery from Exhaust Gas of GT-
HRSGs & flue gas of furnaces.
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This is an important area of energy saving explored during the study. Under this,
thrust is given to implement the new technologies and also to replace the
existing inefficient system with a new and efficient systems. Refinery is losing
substantial energy through hydrogen rich fuel gas to flare, loss due to
condensation of steam and inefficient condensate recovery systems.
As a part of this, new energy saving schemes like use of electrical tracing /
heating in place of steam tracing / heating, plate type heat exchangers in
SWS/ARU, flare gas recovery, and fan less cooling towers in place of
conventional induced draft cooling towers are also recommended.
The schemes that are recommended, as part of this area of energy study are
recovery of hydrogen from refinery off gases, change of condensing turbine /
back pressure drives to motor drives in FCC, reduction of VDU-I column top
pressure, rationalization of air compressors.
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Any energy saving scheme, if implemented in the refinery will most of the time
affect the steam network and / or power network. Therefore, these facilities need
to be optimized. In the current scenario, a complete steam and power network
balance has been carried out for the scenario in which all the energy schemes
accepted by IOCL-HR are assumed as implemented. The energy saving
measures identified in this area are
The comprehensive findings under this section are summarised in Figure 6.1
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120000
98400
100000
80000
60000
40000
19200
20000 11000
10000 9500 7750
915
0
As a part of EEI study, walk through performance audit has been carried out by
expert team constituted by CHT. The committee comprises of representatives
from various refineries, CHT and EIL. The major findings are summarised below
along with energy savings. Further, the list of audit findings is enclosed.
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Presently, it is observed that 20, 000 Nm3/hr air is being vented in MAB. The
blower is driven by condensing turbine, which consumes 32.5 TPH of MP
steam. It is recommended to review the tuning of Anti-surge controller and
critical speed of turbine / compressor to optimize the blower operation.
Venting of air, % = 25
Energy Loss, KW = 1500
MTOE Savings = 2100
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SECTION 7.0
GENERAL RECOMMENDATIONS
&
BEST PRACTICES
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At the heart of a refinery lies the equipment and they consume considerable
utilities for their operation. Efficient utilisation of these equipment’s and utilities
reduces the energy consumption. The Refineries have adopted many best
practices for efficient energy use by developing regular maintenance schedules
which also improves the reliability and thus profitability due to less down time
and higher availability.
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Refinery has various fired equipments like Furnaces, Reformers, Boilers etc.
consuming large amount of energy. Regular monitoring of the equipment is
essential to control the energy loss.
Controlling air to fuel ratio by adjusting the draft and burner air registers
based on varying loads
Installation & regular calibration of Fuel oil and fuel gas flow meters
Replacing Fuel oil with clean fuels like Natural gas for improved back end
recovery and lesser steam load etc.
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7.3 Recommendations and Best Practices for Steam and Power network
Steam and power are the major utilities that are consumed in the refinery
complex, constituting ~ 50 % of total energy needs. Thus optimum generation
and consumption of these utilities helps in efficient energy usage.
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Motors and Turbines are drivers which consume power and steam, respectively
to drive the equipments like pumps, compressors, blowers etc. Operating these
equipments at optimum conditions thus reduces utility consumption.
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7.6 Recommendations and Best Practices for Heating, Cooling & Process
Integration
Heating, cooling and process integration plays a crucial role in the overall
refinery processes. Energy efficient integration of these in the process can help
reduced consumption of utilities like steam and power.
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Carrying out overall pinch analysis of a particular unit and total site pinch
analysis for optimum utility use
Refinery consumes many utilities other than steam and power like cooling water,
instrument air, nitrogen etc. Steam/ power is consumed in generation of these
utilities and thus optimum utilisation of these improves energy efficiency of the
refinery.
Adopting various surveys like air leak survey, control valve survey, flare loss
survey and insulation survey etc.
Reducing flare losses by properly monitoring and reporting by installation
and regular calibration of flow meter
Maintaining Cooling water temperature / pressure / flow by maintaining
condensers to regulate off-gas loss.
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Modelling and testing a design before implementation helps to save time and
money, and allows testing of various ideas for troubleshooting the problems.
Also, doing preventive analysis much before it becomes a big problem, for e.g.
Combustion air duct analysis for age old heaters for change in feed pattern or
fuel pattern etc. helps the refiners in a big way.
Cavitation study
Combustion study
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ANNEXURE – I
OBSERVATIONS OF
PERFORMANCE AUDIT TEAM
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As a part of study, Walk-through Performance Audit has been carried out during
site visit dated 3rd - 4th Nov ’17 by expert team constituted by CHT. The committee
comprises of representatives from various refineries, CHT and EIL. The major
findings are summarised below along with energy savings.
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COMPREHENSIVE STUDY FOR Annexure-II
ENERGY & PERFORMANCE IMPROVEMENT Page 1 of 4
ANNEXURE – II
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COMPREHENSIVE STUDY FOR Annexure-I
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12 LOB Install VFD for Air Handling Units AHU 12,363 1 1 1 0.87
Motors
13 GT Install VFD to AHU Motors-1 13,646 1 1 1 0.92
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COMPREHENSIVE STUDY FOR Annexure-I
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