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Indian Oil Corporation Ltd., Gujarat Refinery, Vadodara

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Indian Oil Corporation Ltd., Gujarat Refinery, Vadodara First Prize Refinery INDIAN OIL CORPORATION LIMITED Gujarat Refinery, Vadodara (Gujarat) Unit Profile IndianOil Gujarat Refinery was dedicated to the Nation in 1966 changing the landscape of a town, a state and the country. Today, Gujarat Refinery is the Flagship Refinery of IndianOil, India’s largest commercial enterprise with a sales turnover of Rs. 4,50,756 crore in 2014-15 and highest Indian corporate in Fortune’s prestigious ‘Global 500’ listing of the world’s largest corporates. The expansion in Gujarat Refinery has taken place in phases over the years from 2 Million Metric Tonnes per year to the present capacity of 13.7 MMT per year and is gearing up for further expansion. Gujarat Refinery and the city of Vadodara have been witness to each other’s phenomenal growth. Gujarat Refinery is the 3rd Refinery of IndianOil and is situated at Jawahar Nagar, nearly 10 km North of Vadodara. The Refinery is spread over an area of 1950 acres including Asoj and Dumad terminal. The first crude distillation unit, Atmospheric Unit-I (AU-I) of 1.0 MMTPA was commissioned in October 1965. Gujarat Refinery is designed to processes indigenous as well as imported crude oil. 268 Today, Gujarat Refinery is the Mother Industry of Vadodara and is catering to the increasing energy demand due to the fast-paced development and economic prosperity of the vibrant state of Gujarat. The Refinery has been playing a catalytic role in encouraging over 200 small and big industries over the course of five decades. One of the most complex refineries in India, Gujarat Refinery has about 40 operating units. Over the course of five decades, the Refinery has kept up with the latest technological advancements and boasts of every modern unit and technology that is available in the IndianOil, Oil & Gas industry today. Gujarat Refinery is also privileged with the distinction of setting up the country’s first Fluidized Catalytic Cracking Unit (FCCU) in 1982 and the first Hydrocracker plant in 1993. The country’s first Diesel Hydro Desulphurization Unit (DHDS) to reduce sulphur content was set up in 1999 to meet BS-II quality of HSD. MS Quality Improvement Project comprising of Continuous Catalytic Reforming Unit (CCRU) and revamp of DHDS were carried out in the years 2006 and 2007 respectively to meet BS-III MS and HSD quality respectively. Further, the Resid Upgradation Project (RUP) and MS/HSD quality improvement project were commissioned in 2010-11. Gujarat Refinery is now gearing up for 100% supply of BS-IV fuels and capacity expansion to 18 MMT per year. In 2004, the world’s largest single train Linear Alkyl Benzene (LAB) Plant was set up in the refinery marking IndianOil’s big-ticket entry into the Petrochemicals field. Today, the refinery holds the 2nd largest market share of LAB in India and exports to over 20 countries. State-of-art Central Effluent Treatment Plant (CETP) has been installed to meet the revised MINAS specifications. Total treated effluent recycling in the cooling tower is already been in place as a part of IndianOil’s fresh water conservation policy. The green belts, spread across an area of 139 acres in and around the refinery speak volumes about its commitment towards environment. With more than two Lacs strong tree population Gujarat Refinery’s three green belts act as lungs for the refinery. A beautiful Eco Park has been developed inside the green belt area surrounded by the pond which is a haven for various bird species. Gujarat Refinery has full-fledged Effluent Treatment Plants consisting of physical, chemical, biological & tertiary treatment facilities. Various measures have been adopted for control of gaseous emissions. Water conservation is another important area being vigorously taken up in refineries through its quality control, re-use of treated water and maximum use in cooling systems. Gujarat Refinery has strong safety management system and infrastructure with focus on behavioral safety. 269 Being an integral part of the city of Vadodara, Gujarat Refinery is committed to improving the quality of life in communities in and around the refinery and the city. Under CSR initiatives Gujarat Refinery has taken up projects for ensuring Clean Drinking Water, Health and Medical Care and Education in the nearby villages and communities. Gujarat Refinery is also accredited with ISO-9001: 2008, ISO-14001: 2004 OHSAS 18001: 2007. Energy Consumption Gujarat Refinery has two Co-Generation Power plants (CGP-1 & CGP-2) and one Thermal Power Station (TPS). Steam and Power Generation Capacities are as below: Steam Generation Power Generation Particulars MT/hr Particulars MW TPS TPS Boiler-1 (HP) 75 STG-1 12 Boiler-2 (HP) 75 STG-2 12 Boiler-3 (HP) 75 STG-3 12.5 Boiler-4 (HP) 130 Sub-total 355 Sub-total 36.5 CGP-1 CGP-1 HRSG-1 (MP) 105 GT-1 30 HRSG-2 (MP) 105 GT-2 30 HRSG-3 (MP) 105 GT-3 30 Sub-total 315 Sub-total 90 CGP-2 CGP-2 HRSG-4 (HP) 100 GT-4 30 HRSG-5 (HP) 100 GT-5 30 HRSG-6 (HP) 125 GT-6 30 Sub-total 325 Sub-total 90 Total - HP 680 Total - MP 315 Total 995 Total 216.5 The average steam and power load of the refinery are 505 MT/hr Steam (HP+MP) and 110 MW Power. By optimising the power plant operations in TPS Boilers 1,2 and 3 are idled. And in the process of energy conservation, fuel loss reduction STG 1, 2,3 are also idle. 270 Energy Conservation Measures Gujarat refinery has implemented various energy conservation measures over the years and has successfully reduced its energy intensity index (EII) from 151 in 2010-11 to 106 in 2014-15. 22 Nos. of ENCON measures were taken up in 2014-15 which has resulted in saving of 39556 SRFT on an annual basis. 271 ENCON Measures at Fuel savings Gujarat Refinery obtained SRFT/yr LP steam generation from FCC LCO stream 500 APH replacement in AU1 500 Hand control provision in K-1(Pre-frac) of AU1 and AU2 to flare 1700 MP steam line from ISOM to FCC commissioning (15 MT reduction of HPS and 15 MT increase in MPS). 660 Anti surge closing (from 15 % to 0%) in DHDT RGC (MP steam consumption lower from 42 MT/hr to 38 MT/hr) 2666 AU5 desalter wash water inlet temperature improvement by E12D/E/F heavy naphtha vs wash water exchanger 1148 Routing H2 rich off gases of CRU to Hydrogen header instead of FG(H2 of ~ 0.35 T/hr) 7850 Stopping of H2 venting to FG from HCU MUG suction 1625 Coker WGC speed reduction 1846 Blow down tower 8 nos. of fans having 30 KW rating are being stopped, while there is no blow down (Total saving 2.4 MW) 1960 Online furnace cleaning in AU1, AU2, AU3, AU4, AU5, VDU, FPU1, FPU2, VBU, MSQ-NHT & CRU -NHT 1200 Dead band implementation in identified 35 locations 2800 In VGO HDT 10 nos. of steam tracing manifold provided for steam tracing to hot lines( having temperature more than 150 o C) have been isolated, as hot lines heat tracing is not required in normal operation. Steam saving 1.0 MT/HR 457 Operation of DHDT at 110 kg/cm2g system pressure. Design is 117 kg/cm2g. (2 MT/hr HPS saving) 2462 Cooling water pumps to be stopped (winter operation optimization) 2.705 MW 5227 Cooling Tower fans to be stopped (winter operation optimization) 0.305 MW 665 Units Air Fin coolers to be stopped (winter operation optimization) 0.766 MW 1456 Ejector steam optimization 576 Steam optimization in DCU-WGC Turbine 1846 Extraction mode in CRU RGC 1412 LAB GAS OIL reduction 1000 272.
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