Certificate of Merit Petrochemicals

OIL AND NATURAL GAS CORPORATION LIMITED Hazira Plant, ()

Unit Profile

Hazira Plant, set up in 1985 & the largest sour gas-processing complex in the country, has presently been processing about 34-35 MMSCMD of Sour Gas and approx 5000-6000 M3/ day of Sour Condensate to produce Sweet Gas & Value Added Products, viz. – LPG, Naphtha, SKO, ATF, HSD & Propane. The feedstock in the form of Sour Gas and Sour Gas Condensate is received from different fields, of B&S Asset of ONGC and PMT-JV consortium, located in Mumbai offshore. Hazira Plant Complex sprawls over an area of about 640 hectares with approx. 19 Kms of peripheral boundary wall. Plant has a direct strength of 820 employees.

The Plant is of strategic importance to the nation as the 3000 Km HVJ Pipeline emanates from Hazira Plant. It is the life line to scores of industries ranging from Fertilizer to Power, Petrochemical, CNG, Domestic Supply, Ceramic and others in 6 states of .

252 The state-of-the-art process facilities developed at Hazira Plant and its role in overall national economy makes it a jewel in the crown of ONGC. The plant has kept pace with the latest developments in the world to upgrade the technology and safe working practices. An integrated QHSE Management System has been in place incorporating the international accreditations of ISO-9001:2008, ISO-14001:2004 & OHSAS-18001:2007. Health, Safety and Environment is the foremost concern with elaborate provisions using latest concept and gadgets for safety, effluent treatment plants and 30% of total land is maintained under flora & fauna (Green Belt).

Hazira Plant also produces power at its Cogeneration Power Plant through three gas turbine generators, totaling about 60MW capacity. Electric power to all the facilities of the Plant as well as to the township is supplied by the Cogeneration unit and the surplus power is wheeled and exported to C2-C3 Plant Dahej & Mehsana Asset of ONGC and GEB, respectively.

Hazira plant is self-contained with all utilities & offsite facilities such as water system, air system, inert gas system, effluent treatment plants, product storage and dispatch facilities, fire and safety system etc. for safe and smooth operation of the plant.

Energy Consumption

Energy Consumption details 2013-14 2014-15

Total consumption of electricity 2660.34 2529.90 (purchased + own generated electricity consumption within the plant) (Lacs kWh/ year)

Total Electricity Consumption 22878.95642 21757.10844 in MTOE (Metric tonne of oil equivalent)

Fuel Consumption for process heating 2013-14 2014-15

STEAM L P M P H P L P M P H P

Quantity used for process heating (tonnes/ year) 1144589.2 1197417.25 613051.41 1339801 373100 651323

Weighted Av. Gross Calorific value 662000 667000 669000 662000 667000 669000 (GCV) (kCal/ Ton)

Total heat value of steam used (Million kCal/year) 757718.05 798677.31 410131.39 886948.26 248857.70 435735.09

Total heat value of steam used 1966526.75 1571541.047 (Million kCal/year)

Absolute Savings and its percentage over previous year energy consumption

Elect. Saving Thermal Elect. Thermal % Elect. % Thermal (Lac kWh) (Fuel) Consumption (Fuel) Saving (Fuel) Saving in 2014-15 Saving (lac kWh) in Consumption (savings achieved/ (savings achieved/ (Million kCal) 2013-14 (Million kCal) electricity thermal energy in 2014-15 in 2013-14 consumption of consumption previous year) of previous year)

(i) (ii) (iii) (iv) (i) / (iii) x 100 (ii)/ (iv) x 100

130.45 394985.703 2660.34377 1966526.75 4.903501625 20.08544776

253 Energy Conservation

Waste Heat Recovery:

Exhaust from the Gas Turbines is utilised in 3 Heat Recovery Steam Generators(HRSG). By utilizing heat value of the fuel to the maximum extent (in HRSG), Hazira Plant saves on precious resource (natural gas) as well as reduces pollution & ensures emission on lower temperature.

254 Savings:

Year Steam from HRSG Saving in waste Heat (MT) Rs. (Lacs) 2013-14 1052767.16 5661.36 2014-15 1257747.01 6763.66

Turbo Expander:

It works on Iso-entropic process. The work produced during expansion is conserved and utilized for compression of the lean gas, thus makes it highly energy efficient.

Year Energy Saving (KWH) Saving in Rs. (Lacs) 2013-14 16409910 311.79 Other2014-15 Energy Conservation Measures11624584 220.87

Year Project description Annual Total Investment saving savings incurred on (Lac units) (Rs. Lacs) the project Rs. (Lacs) 2013-14 Revamping of central AC plant at 3.61008 25.992576 99 Admn. Building including replacement of 25 years old reciprocating chiller unit & single screen Air Handling Units (AHU) with latest technology of Screw Chillers & VFD (Variable Frequency Drive) controlled Double Screen AHU’s. 2013-14 12 No. compressor house Lighting 2.73312 19.678464 0.18 made on auto mode (Timer mode) with in-house efforts. Total 240 Nos. 250W HPMV lights were made glowing in night time only. 2013-14 Installed 3000 Lts. per day capacity 0.26280 1.89216 5.5 Solar Water Heating system (6 nos. x 500 LPD) at ONGC Guest House. 2014-15 Replaced 27 nos. of AHUs with 6.8766 49.51152 140 energy saver double skin AHUs where-in air flow is controlled by VFD. 2014-15 Installed movement detectors in 3.03648 21.862656 5 Sub-stations Lighting System as energy saving measure.

255 Energy Policy

Energy Policy – Main Points

Energy Conservation

 Create Awareness all round by audiovisual means.  Emphasis on effective use of energy in any form.  Incorporate energy efficient design of systems in plants and equipments (including transport equipments)  Use heat recovery systems and utilize the same for steam generation, process heat requirement, air-conditioning etc.  Strict observation of methods of good housekeeping, best up-keep of devices/equipments  All schemes & systems to have energy budgeting with clarity of its use & efficiency  Conduct Energy Audit every year of all installations with connected load above 500KW

Assist in Development of alternate sources of energy

 Encourage use of Solar, Wind, Wave/Tidal, Hydel (run-of-the- river) & Hydrogen Energies for installations, townships & automotive applications wherever feasible and get the Carbon credit by reducing the carbon emission. Also avail the energy subsidies.  Encourage development of Bio-Gas centers for residential townships.

Promote Conservation of Oil

 Use of CNG as replacement of diesel, Kerosene etc.  Use of Natural gas as direct fuel.  Generate Energy by own power plant for internal use of plants wherever gas is available instead of buying electricity from the supply companies.  In case of marginal fields, where the gas is available a small gas generating set/ gas turbine can be installed and power generated and sold to power trading corporation, electricity boards through a contract.

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