Indian oil corporation barauni refinery

• 1. BARAUNI REFINERY INDIAN OIL CORPORATION Barauni (Bihar)(i) Unit Profile Barauni Refinery is the second Public Sector Refinery of Indian Oil Corporation built in collaboration with erstwhile USSR and limited participation of Romania. It is located near the northern bank of river Ganga in Begusarai district of Bihar. The refinery went on stream in the year1964and wasformally inaugurated by Prof. Humayun Kabir, the then UnionMinister for Petroleum & Chemicals, Govt.of India on15th January,1965. The installed capacity of crude oil processing has been enhanced from 3.3 MMTPA to 6.0 MMTPA since Jan2003 after commissioning of process units like RFCCU, DHDT, HGU, SRU, ARU & SWS.During the year 2003-04, Barauni Refinery processed 4.3 MMTPA crude oil. The differentpetroleum products produced by Barauni Refinery are LPG, Naphtha, Motor spirit, SuperiorKerosene Oil, High Speed Diesel, Light Diesel Oil, Raw Petroleum Coke & Sulphur.Barauni Refinery caters to the Oil requirement of large number of customers of Northern WestBengal, Bihar, Nepal and part of U .P.Barauni Refinery In harmony with nature

2. 20 (ii) Energy Consumption :Refining of crude oil being an energy intensive activity, the major chunk of expense in theprocess is the energy cost. Therefore, the need of energy conservation is of utmost importance.This leads to not only increase in profitability in the form of lower energy cost and adding on tothe bottom line but also protection of environment and quality of life. Due efforts were made bythe refinery and various energy conservation measures like yield and energy optimisation ofdistillation units (AVU-I, II & III) & Coker-A & installation of high efficiency Gas Turbine. Oldconventional pneumatic systems used for operational controls have also been replaced withDistributed Control System in all process units and OM&S. These measures along with day today monitoring of fuel & loss helped to bring down the energy consumption level from 171MBTU/BBL/NRGF in 1990-91 to 133.8 in the year 2003-04.UNIT2001-02 2002-03 2003-04 CRUDEMMT 2.91 2.99 4.30 COKER TPUTMMT 0.67 0.65 0.45 RFCCUMMT -0.50 1.02 DHDT MMT -0.71 2.17 HGUMMT -0.04 0.92 PROCESSING COST RS / MT OF CRUDE FUEL & LOSS% 6.99 11.4*10.2 NRGF 2.85363.8312 3.8636 MBTU/BBL/NRGF 135.4146.09 133.8* Includes 1.25 % F&L towards BXP units(RFCCU / DHDT / HGU / SRU / ARU / AWS)commissioning.Barauni Refinery In harmony with nature 3. ENERGY + LOSS PERFORMANCE ENERGY COST (MBTU / BBL / NRGF)(% OF MANUFACTURING COST) 150 45146.09 39.6 145 4038.3 140 35135.4 135 133.8 30 26.9 130 25 125 20 01-02 02-0303-0401-02 02-03 03-0420 (iii) Energy Conservation Commitment, Policy and Set Up :To conserve energy, optimisation of the operation of the process heaters and boilers andmaximum possible heat recovery from out going streams have been given utmost emphasis inday-to-day refinery operations. The efficient usage of utilities, optimisation of steam-powerbalance, and optimization of heat exchanger train have been the prime concern in the EnergyConservation area.As a broad classification the energy conservation activities have been grouped under long termand short term ones. The long-term activities are the high investment projects spread over along period. The short-term measures consist of continuous efforts for energy optimisation.The specific energy consumption is monitored daily/weekly/monthly for effective control. Theoptimisation of process conditions and implementation of energy conservation scheme is giventhe highest priority.Energy Conservation fortnight is celebrated every year from 15th Jan to 31st January. Variouscompletion like essay, slogan, poster on energy saving and cycle rally & in-house seminar isconducted. Barauni Refinery In harmony with nature 4. The importance of energy conservation is emphasized through TPM (Total ProductiveMaintenance) by achieving zero breakdown, zero defect culture. Barauni Refinery has startedTPM implementation in October2002 and Coker-A unit has been selected for implementation ofPilot model by April2004. TPM was formally Kicked off on 30th Aug2004 after successfulimplementation of Pilot Model at process unit. Refinery wide implementation of TPM is plannedto be completed by 2007 end.Right from the beginning Barauni Refinery has an exclusive Energy Conservation Cell formonitoring energy consumption and implementation of ENCON measures.Energy Conservation Team Structure UNIT HEAD EXECUTIVE DIRECTORGENERALMANAGER (Tech)DY. GENERALMANAGER (TS) TA & ENCON CELLReview existing energy level and Hydrocarbon loss.Set Plant / Area wise targets and monitor the actualperformance.Benchmark energy consumption and losses.Carrying out audits / surprise checks.Initiate ENCON projects, schemes etc.Conducting surveys like:Process ProductionCaptive PowerMonitoring Cell Managers Plant, Utilities & OffsitesBarauni Refinery In harmony with nature 5. 20 (iv) Energy Conservation Achievements:The major projects implemented during 2003-04 are as under: 1. Effective Utilisation of HRSG-II A fuel efficient Gas Turbine system was commissioned on 11th Dec 02 and Heat Recovery Steam Generator was taken on range and put on load with Gas Turbine on 21st Feb 03. The estimated yearly benefit is 16649 SRFT /Yr. which is equivalent to 1753 Lakhs / Year.2. Installation of new Vacuum Ejector in AVU-IINew three stage ejectors comprising of two ejectors in each stage were commissioned in AVU-II in Apr2003. The O/H oil separated in hot-well goes through a coalescer for injection to Diesel.Benefits:The installation of ejectors has reduced the steam consumption from the earlier value anderadicated the use of 40 ata steam for that purpose. The system has also removed the thirdwater system for which a separate cooling tower was being operated.The incorporation of coalescer along with this system has also reduced the slop generationdecreasing the load on ETP and reducing the hydrocarbon loss. The HC recovered in thecoalescer are being directly routed to diesel pool. Estimated benefit of the installation ofVacuum ejector is 1496 SRFT/yr which is equivalent to Rs. 149.6 Lakhs / Year.Barauni Refinery In harmony with nature 6. 3. Commissioning of Air Coolers in AVU-IISince inception of the unit, the overhead systems ofK-1 and K-2 were equipped with water condensersfor condensing the overhead vapours from K-1 andK-2.During the M&I of AVU-I four air-condensers for K-1(AC-101A/B/C/D) and four air-condensers for K-2(AC-102A/B/C/D) were installed for condensing theoverhead vapors cooling tower was being operateThe condensed vapors from the air condensers are further cooled down in trim to bring downthe temperature of the condensate to 40C.Provision of these air condensers has reduced the cooling water consumption; maintenancecost incurred to clean the water condensers on regular basis and has helped to increase theefficiency of the system. Estimated benefit of the installation of Vacuum ejector is 570SRFT/Yr. which is equivalent to Rs. 60 Lakhs / Year.4. Commissioning of APC in AVU-I / II / IIIAdvanced Process Control (APC) has been implemented in Crude distillation units i.e. AVU-I /II / III in Aug03 at an investment cost of Rs. 71.25 Lakhs. Process control that has features ofoverall online process control for optimized operation based on objective functions provided.Based on the process conditions / disturbances it derives inferential predictive performanceand accordingly adjusts process conditions. A more steady and optimized operation isachieved. Estimated benefit of APC is 1900 SRFT /yr which is equivalent to Rs. 200Lakhs/Year.Barauni Refinery In harmony with nature 7. 20 (v) Energy Conservation Plan & Targets:To improve the energy performance further, the following major projects are underimplementation / active consideration :SL.PROJECTS / MODIFICATIONS TARGETANNUAL ANNUALNO (YEAR) SAVINGSSAVINGS (SRFT) (Rs. Lakhs)1.Installation of BMS in TPS Boilers.2005180 182.Stoppage of operation of CRU cooling 2004 390 39tower and connecting the CW system withPCT.3.Insulation of 9 nos. of RCO / LSHS tanks 200518001804.Recovery of reactor blow down in Coker-20051200120A5.Heating of desalter washwater by 2005 600 60desalter brine in AVU-I/II6.Installation of TPI in ETP 2005 150 157.Heat recovery from RFO stream in Coker-20051700170A by steam generation @ 3 MT/Hr8.Revamping of heat exchanger network20065000500and fractionation improvement in AVU-I&II9.Hydrogen recovery from CRU off gas 200513600 136010. Flare management with provision of LPG 20051200120vaporizerTotal25820 2582With the implementation of above energy conservation projects, specific energy consumption ofthe refinery will about 112 MBTU/BBL/NRGF.Barauni Refinery In harmony with nature 8. 20(vi) Environment Management System:Barauni Refinery has a full-fledged Environment Protection Cell. The worth noting is that thiscell was established 28 years back in 1975. In Indian oil, Environment Protection has alwaysremained a thrust area. The Environment Protection Cell having qualified engineerscoordinates all the activities required to achieve continuous improvement in environmentalperformance related to Environmental Management in the Refinery. The goals and functions ofthe cell are: Toachieve reduction of wastesand releases giving preference first to source reduction, second to recycle / reuse and third to treatment and thereby maintaining effluent and emission standards within the permissiblelimit and legislative requirements. To obtain legislative sanctions viz. emission andeffluent dischargeconsent, NOC, Environment Clearance for new projects and to achieve compliance with NOC and EC conditions. To establish prevention mechanisms by application of engineering and operational control. System development with environment friendly. replacement/improvement within and around the Refinery. Training / awareness programs in the areas SOME VIEWS OF ECOLOGICAL of environment protection within and aroundPARK the Refinery. The Refinery has a beautiful ecological park spread over an area of 75 acres. The park Barauni Refinery In harmony with nature 9. developed with in-house expertise and resources has lush green lawns large variety of treesand shrubs and the wonderful ECO pond where flora & fauna and aquatic life are thriving ontreated effluent. The surrounding tranquil environment of the ECO pond of park attractshundreds of migratory birds every winter. It is a testimony of refineries dedication to fosteringenvironmental excellence and enhancing quality of life in the region.Barauni Refinery had developed Environmental Management System conforming to theInternational Standards, ISO-14001 and Integrated the same with International QualityManagement Standard, ISO-9001:2000 and with the Occupational Health Management Systemconforming to OHSAS-18001:1999. Refinery thus developed an Integrated ManagementSystem called SHEQ System. SHEQ Policy, a set of objectives and time bond action plan areset for the continual improvement and customer satisfaction in the area of Safety, Health,Environment & Quality.ECOLOGICAL PARKECOLOGICAL PARKTreated Effluent Quality: PARAMETERSMINAS LIMIT 2003-2004 (AVG.)pH6.0-8.57.55OIL & GREASE, mg/litre 105.4PHENOL, mg/litre 1.00.026BOD, mg/litre15 9.75SULPHIDES, mg/litre0.50.29TSS, mg/litre2016.8 Barauni Refinery In harmony with nature 10. 100% compliance of effluent quality with MINAS since 1990. Maximum recycle of treated effluent. Nil discharge to river Ganges except in Monsoon.Emission Control:The major air pollutant from the Refinery is SO2. The SO2 emissions are controlled right at thesource through use of low sulphur fuel in the furnaces and boilers. The stack emissions aremonitored periodically for SO2, NOx, CO and SPM and have been found to be well below thelimit specified by the CPCB as well as BSPCB.UNITSTIPULATIONS ACTUAL (AS PER MOE&F)SO2 EMISSIONSO2 EMISSION AVUKG/ MT of crude processed0.25 0.151 RFCCUKG/ MT of feed2.5 0.28 TPSKG/HR (MAX.) 12894 REFINERY KG/ HR 1080 450Safety Management System:Barauni Refinery has an elaborate Safety Management System. Refinery is following stringentOil Industry Safety Directorate (OISD) standards and other Rules/ Acts as applicable. PeriodicSafety Audit of the facilities and system is carried out. Each recommendations status isthoroughly discussed in the monthly Health & Safety Committee Meeting chaired by the topmost official of the company. No efforts are spared to fulfill recommendations arising duringSafety Audit, in shortest possible time.To take care of the Safety of the refinery and surrounding and to minimise the impact of theprobable emergencies, viz fire, explosion, toxic gas release etc., Refinery has prepared On-SiteDisaster Management Plan and Off- Site Disaster Management Plan, and both are dulyapproved by competent authority. Material Safety Data Sheet (MSDS) consisting of paramountproperties of chemicals & their safe handling is a part of Disaster Management Plan. To checkthe efficiency and bring improvement in the plan, periodic On-Site & Off Site mock drills areconducted.Barauni Refinery In harmony with nature 11. ----- End -----Barauni Refinery In harmony with nature 12. MAIN PRODUCTSLPG :LIQUEFIED PETROLEUM GASMS:MOTOR SPIRITNAPHTHA :NAPHTHAHSD :HIGH SPEED DIESELSKO :SUPERIOR KEROSENE OILMTO :MINERAL TURPENTINE OILLDO :LIGHT DIESEL OILLSHS:LOW SULPHUR HEAVY STOCKRPC :RAW PETROLEUM COKECPC :CALCINED PETROLEUM COKEP. EXT. :PHENOL EXTRACTSL. WAX :SLACK WAXBarauni Refinery In Harmony With Nature 13. NAME OF PROCESS UNITSAVU-I:ATMOSPHERIC & VACUUM UNIT-IAVU-II :ATMOSPHERIC & VACUUM UNIT-IIAVUIII :ATMOSPHERIC & VACUUM UNIT-IIIPEU:PHENOL EXTRACTION UNITSDU:SOLVENT DEWAXING UNITCCU:COKE CALCINATION UNITNSU:NAPHTHA SPLITTER UNITCRU:CATALYTIC REFORMER UNITRFCCU:RESID FLUID CATALYTIC CRACKING UNITDHDT :DIESEL HYDROTREATER UNITHGU:HYDROGEN GENERATION UNITSRU:SULPHUR RECOVERY UNITARU:AMINE REGENERATION UNITSWS:SOUR WATER STRIPPER Barauni Refinery In Harmony With Nature 14. IndianOil Energy Policy To be a World Class performer in energy managementBy Adopting energy efficient and environment friendlytechnologies. Benchmarking our performance with the best in the worldand endeavoring to be ahead. Promoting use of renewable sources of energy. Fostering a culture of participation and innovation amongststake holders forcontinualimprovementin energyconservation. Propagating the message of avoiding wastage of energy tothe community.Barauni Refinery In Harmony With Nature 15. 1. EFFECTIVE UTILISATION OF HRSG-IIBackground :To cater the power requirement of refinery @ 6.0 MMTPA after implementation ofBarauni Refinery Expansion Projects, a 20 MW Gas Turbine along with Heat RecoverySteam Generator of capacity 48 MT/Hr (Pr.=40 ata , Temp.= 440oC) has been installed.Fuel efficient Gas Turbine system was commissioned on 11th Dec 02 andHeatRecovery Steam Generator (HRSG) was taken on range and put on load with GasTurbine on 21st Feb 03. The stabilised operation of HRSG was started in 2003-04.Observation Made :The steam generation through HRSG is 37 MT/Hr at a power load of 13 MW on GasTurbine.Technical & Financial Analysis Made :Power Load on Gas Turbine 13MWFuel (Naphtha) consumption5 MT/HrEquivalent SRFT 5.2 MT/Hr0.40MT/MwSteam Generation through HRSG 36MT/HrEquivalent SRFT 2.6 MT/HrNet fuel consumption in Power generation through Gas Turbine2.6 MT/Hr Barauni Refinery In Harmony With Nature 16. 0.20MT/MwSavings SRFT by stopping one Boiler 16649 MT/Yr1753Rs. Lakh/YrImpact of implementation :Operation of one boiler stopped.2. INSTALLATION OF NEW VACUUM EJECTOR IN AVU-IIBackground :Steam jet ejectors were used for producing vacuum in the vacuum column with MP (10ata) steam being used as the motive force.The vacuum system utilised direct contact of cooling water with vacuum columnoverhead vapour and steam coming out from column top resulting in mixing ofcondensed oil and circulating water. This mixture was sent to a dedicated oily watersystem (called as 3rd cooling water system). Since the emulsion of oil and water was verydifficult to break, this resulted in higher slop generation and subsequently higherhydrocarbon loss.Due to the use of direct contact type condensers a separate circulating water systemwith cooling tower and API oil separator was required. The oil separated from these APIseparators had to be recovered as slop oil and had to be reprocessed in the crudedistillation unit(s). It may also be noted that total recovery of oil was not feasible andnearly 40% - 45% of the oil resulted into loss.It is evident that the above mentioned system was energy inefficient and prone to higherslop generation/ hydrocarbon loss. A separate cooling water system with hot and coldwater pumps, cooling tower fans and API oil separators had to be separately maintainedfor vacuum producing system.To reduce energy consumption and hydrocarbon loss the vacuum producing system ofAVU- II was revamped with the latest vacuum producing system consisting of thefollowing items - Shell and tube type pre-condenser and primary inter-condenser using refinery cooling water as cooling media. Two stage steam ejector system. Barauni Refinery In Harmony With Nature 17. Necessary piping and instrumentation.Observation Made :Elimination of direct contact type ejector condensers resulting in reduction ofhydrocarbon loss.Savings in power consumption due to elimination of dedicated cooling water systemused for direct contact type condensers.Technical & Financial Analysis Made :A. Reduction of Hydrocarbon Loss: Sl. No. ParticularsQuantity (MT/ Day) 1. Vacuum slop generation (@ 5000 MT/Day9.6Tput) 2. 30% of the vacuum slop skimmed off and 2.88recovered in AVUs. 3. Slop carry over with 3rd system of circulating 6.72water (1 2) 4. Slop recovery from API Separators (55%)3.70 5. Hydrocarbon loss (3 4) 3.02Annual Savings 997 MTB. Reduction in Power Consumption: Sl. No. ParticularsQuantity (KWH) Savings from removal of 3rd system of circulating water 1. Reduction of 2 Nos. of hot well pumps 2 X 75 KW 2. Reduction of 2 Nos. of cold water pumps 2 X 75 KW 3. Reduction of 3 Nos. of CT fans3 X 28 KWTotal Power Consumption 234 KWHBarauni Refinery In Harmony With Nature 18. (considering 1 hot well pump, 1 cold water pump and 3 CT fans running) Power consumption in revamped vacuum producing system - 1.2 Nos. of hot well oil pumps2 X 18.5 KW 2.2 Nos. of oily water pumps2 X 5.5 KW Total power consumption 24 KWH (considering 1 hot well oil pump and 1 oily water pump running) Net Power Consumption, (234 24) KWH 210 KWH Net Annual Power Saving 1663 MW Equivalent Annual Fuel Saving 499 MT (considering 1 MW = 0.3 MT Fuel)Total annual fuel saving and reduction of hydrocarbon loss due to revamp of vacuumproducing system in AVU-II (A + B) = 997+499 = 1496 MTIn monetary terms the savings is equivalent to Rupees 149.6 lakhs/ year.Impact of implementation :Reduction of power consumption and hydrocarbon loss.3. COMMISSIONING OF AIR COOLERS IN AVU-IIBackground :Since inception of the unit, the overhead systems of K-1 and K-2 were equipped withwater condensers for condensing the overhead vapours from K-1 and K-2.During the M&I of AVU-II four air-condensers for K-1 (AC-101A/B/C/D) and four air-condensers for K-2 (AC-102A/B/C/D) were installed for condensing the overhead vapors. Barauni Refinery In Harmony With Nature 19. Observation Made :Provision of these air condensers hasreduced the cooling water consumption,maintenance cost incurred to clean thewater condensers on regular basis and hashelped to increase the efficiency of thesystem. Technical & Financial Analysis Made : Estimated benefit of the installation of Vacuum ejector is 570 SRFT/Yr which is equivalent to Rs. 60 Lakhs / Year.4. COMMISSIONING OF APC IN AVU-I / II / III Advanced Process Control (APC) has been implemented in Crude distillation units i.e. AVU-I / II / III in Aug03 at an investment cost of Rs. 71.25 Lakhs. Process control that has features of overall online process control for optimized operation based on objective functions provided. Based on the process conditions / disturbances it derives inferential predictive performance and accordingly adjusts process conditions. A more steady and optimized operation is achieved. Estimated benefit of APC is 1900 SRFT /yr which is equivalent to Rs. 200 Lakhs/Year. Barauni Refinery In Harmony With Nature 20. BLOCK FLOW DIAGRAM OF PROCESS / PRODUCTION UNITS OF BARAUNI REFINERY FUEL GASLPGCRUMS NAPHTHAKEROSENAVU H2I/ PLANTCRUDE II / DHDTHSDIII COKERLRUA /BIFO RPC ATU/SRUFCCULPG MERICHEMSULPHUREGASOLINE MERICHEM