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HALDIA REFINERY Haldia,West Bengal

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HALDIA REFINERY Haldia,West Bengal HALDIA REFINERY Haldia,West Bengal S. N Name Designation Contact details 01 Mr. E Panthya Chief Manager Lead Presenter [email protected] Mob: 9996140617 02 Ms. Lalitha Rani Assistant Manager Member [email protected] Mob: 9679833427 03 Mr. Amit Kalyan Chandra Assistant Manager Member [email protected] Mob: 9432946618 YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 1.Brief Introduction on company/unit YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth HALDIA REFINERY OVERVIEW SN Attribute Remarks 1 Foundation Stone by Late Prof. Triguna Sen, Hon’ble Petroleum Minister on 6th Dec 1969. laid 2 Area 583 Acres 3 Commissioned in January 1975 4 Located at Haldia, Medinipur (E) District of West Bengal, 130 km from Kolkata. 5 Employees 1529 6 Crude capacity 8.0 MMTPA crude capacity (Capacity revamp for 8 MMTPA done in Jan’20) 7 Crude imported Saudi Arabia, Iran, Iraq, UAE, Nigeria, Angola, Malaysia, Kuwait, America and from Indigenous crudes YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth HALDIA REFINERY OVERVIEW SN Attribute Remarks Arab mix, iran mix, basrah, Kuwait, das, mars, Ural, Maya, Girasol, Clov, Bonny Lt, 8 Crude Basket Labuan AkPO, Bonga, Kissanje, Miri, Agbami, Seria Lt, Murban-LS,WTI midland, Egina, Escravos, Mondo. 34 Nos (CDU1/2,VDU1/2,DCU,OHCU,FPU,RFFCU,DHDS, MHC, CGOT, HGU-1/2, No of process 9 CRU,KHDS, MSQ-ISOM,PRIME-G, LHFU, CIDWU,FEU,PDA,VBU, SRU2/3/4/5, SWSs, plants ARUs ETPs1/2 etc..) 4 STGs:48 MWh 4 Boilers : 525 TPH 10 CPP capacity 3 GTs:60 MWh 3 HRSGs : 360 TPH Total Power :108 MWh Total Steam : 885 TPH Total storage 198Nos 11 tanks Despatch PPL, Rail, Road, Coastal (Barge, tanker), Bitumen bulk loading and drum filling 12 facilities MS, HSD, Kero, ATF, MTO, JBO, Naphtha, Bitumen, Bitumen emulsion, 5 grades of 13 Products LOBS YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth HALDIA REFINERY-Block Flow Diagram ->Stream sharing among the process plants for manufacturing final products like LPG, MS, HSD, Kero, ATF, Bitumen etc.. -> DHDT is under commissioning stage -> H2SO4 plant erection started YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 2. Production Data & Energy Consumption Overview YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth PRODUCTION DATA OF LAST THREE YEARS FY 2017-2020 9000 Figs in TMT 7965 Light Distillate includes: 8000 7655 Production of LPG, Naphtha, MS. 7000 6463 Middle Distillate includes: 6000 Production of ATF, MTO, SKO, HSD, JBO. 5000 4135 Heavy end Distillate includes: 4000 3827 Production of FO, Bitumen, Coke 3221 & Sulphur. 3000 LOBS: 2000 1535 1581 H70,H150 Gr-2/3,H500,150BN 1293 1432 1240 1193 1000 166 174 81 0 • Crude processed in 2017-18 2018-19 2019-20 Year FY2019-20 was less due Crude T'put Light distillates to revamp shutdown of Middle Distillates Heavy end distillates crude processing unit for LOBS capacity enhancement to 8 MMTPA YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth THERMAL AND ELECTRICAL ENERGY CONSUMED IN FY 2019-20 Thermal Energy Consumption FY 2019-20 0.1% • Major sources of fuel are Fuel oil, HSD 7.2% Fuel Gas, Naphtha, naphtha and fuel gas COKE 20.8% Fuel Puge Gas, Fuel Oil Gas HSD, Coke, • Catalyst coke burnt in regenerator 36.8% Naphtha Fuel Oil of RFCCU is used for catalyst/feed 29.9% heating to reaction temperature 5.2% 505 Deg C Note: Figs in % of total thermal Purge Gas energy consumed in Million Kcal Electrical Energy consumption: 485 Million kWh Overall Energy Consumption(Thermal + Electrical): 574031 TOE. YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 3.Energy Consumption in last 3 years (FY 2017-20) YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth OVERALL ENERGY CONSUMPTION OF LAST THREE YEARS FY 2017-2020 99.0 Actual New MBN 88.7 89.0 MBN(SEC)=Million BTU/1000 80.7 Barrels/NRGF 79.0 76.4 NRGF= Equivalent Crude intake for all 69.0 refinery units in KL/Crude processed MBN -> MBN 59.0 in KL 49.0 2017-18 2018-19 2019-20 Year Sp energy Annual % Year Reason for variation consumption TOE improvement Lower secondary units utilization due to total refinery shut 2017-18 80.7 down for taking DYIP project (DCU,CGOT,MHC,SRU-5) hookups. Higher crude unit & secondary utilization with higher 2018-19 76.4 -5.33 energy savings schemes about 18370 SRFT implementation. Higher due to delay commissioning of DYIP units , 2019-20 88.7 16.10 capacity revamp of CDU-1/VDU-2/MSQ/HGU-2 and YEAR OF DIGITALISATIONOHCU/CIDW M&I. Lower crude capacity utilization(86%) Accelerating Efficiency, Empowering Growth BLOCK WISE ENERGY CONSUMPTION OF LAST THREE YEARS FY 2017-2020 Million Kcal in FY 2017-18 Million Kcal in FY 2018-19 Million Kcal in FY 2019-20 407374 448131 177150 431761 428112 546210 964068 417985 1340328 1320880 555946 1291257 947228 1515030 899072 850665 1432317 1878928 2063476 Fuel Oil Block Lube Oil Block Fuel Oil Block Lube Oil Block Fuel Oil Block Lube Oil Block DHDS block OHCU block DHDS block OHCU block DHDS block OHCU block CPP Offsite CPP Offsite CPP Offsite DYIP SN Block/section Process Units SN Block/section Process Units 1 Fuel oil Block CDU-1/2,KHDS,CRU 5 DYIP DCU, CGOT, MHC, SRU-5, SWS, ARU 2 Lube Oil block VDU-1,PDA,FEU,CIDWU,LHFU 6 Captive Power Boilers, STGs, GTs, HRSGs 3 DHDS Block DHDS,VDU-2,MSQ, ARUs, SRU2/3/4, plant(CPP) RFCCU 7 Offsite Storage, Feeding, Despat(TTL, PPL, TW, 4 OHCU Block HGU-2,OHCU Jetty, Barge) YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 4. Energy bench marking and Road map YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth SPECIFIC ENERGY CONSUMPTION (SEC/MBN) ROAD MAP Projected Year Wise SEC/MBN Reduction SEC Reduction Target given by BEE(MOPNG) 94.00 88.73 MBN SN PAT Base line Target Actual 89.00 cycle MBN MBN achieved 84.00 79.00 76.53 1 PAT-2 78.95 73.61 76.087 72.89 (FY2014-15) (FY2018-19) (FY2018-19) 74.00 70.90 69.00 2 PAT-6 76.087 70.87 64.00 (FY2018-19) (FY2022-23) 59.00 MBTU/Bbl/NGRF 54.00 49.00 2019-20 2020-21 2021-22 2022-23 Year SEC reduction in PAT-2 cycle was 3.2% w.r.t baseline. Couldn’t achieve target as DYIP commissioning done in Sep’19 against planned in FY2018-19 Total annual TOE reduction planned to achieve PAT-6 SEC/MBN target is: 60442 TOE YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth MAJOR ENCON PROJECTS PLANNED IN FY 2020-21 Envisaged S. N ENCON Scheme TOE/Yr 01 Recovery of Hydrogen(550kg/h) from Refinery Off-gases 6600 02 Waste Heat recovery from HRSG blow down 676 Hot feed to KHDS unit at 70°C directly from B/L & Increasing the Pre-heat by 3-4°C 03 150 thus reducing the Furnace Duty 04 Maximizing Feed Preheat Temperature in NHT (CRU) unit 550 05 Installation of fan less cooling tower in GT 250 Excess air optimization of the Heater 16-F-01/F101,31-F-01/F-02 by installation 06 660 TDLS analyzer Total 8886 YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth YEAR WISE ENERGY SAVING SCHEMES PLANNED IN 2021-22 Envisaged S.N ENCON Scheme TOE/Yr 01 Routing of UCO to RFCC as hot feed 650 Crude Preheat Temperature Improvement by Pinch Analysis and modifications in Preheat train 02 6000 in Crude Distillation Unit II (CDU II) 03 Steam network reduction by 40TPH from present consumption of 470 TPH 23700 04 Flaring gas recovery from RFCCU Gascon section through modifications 2000 Total 32350 YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth YEAR WISE ENERGY SAVING SCHEMES PLANNED IN 2022-23 Envisaged SN Scheme TOE/Yr 01 Heat Recovery from SR & IO Product Rundowns in VDU I 650 02 Routing of hot VR from VDU-I (during HS mode) to DCU 1556 03 Low End Heat Recovery From Exhaust Gases of DHDS/CIDWU furnaces 400 04 Installation of LRVP in last stage of ejector in VDU-2 3000 05 Implementation of RLNG in boilers/Fired heaters/HGU-1/HGU-2 6000 06 About 10 TPH Condensate recovery from open loop steam traps 5500 07 Switch De-isohexaniser Reboiler in the ISOM Unit from MP Steam to LP Steam (KBC-PR) 700 08 Power Recovery Train (PRT) – in Regen flue gas (KBC best practices) 900 09 Use O2 rich outlet gas from N2 plant in regenerator to increase the efficiency (McK-PDR) 500 Total 19206 YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 5. Energy projects implemented in last 3 years (FY2017-20) YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth SUMMARY OF ENERGY SAVING PROJECTS IMPLEMENTED IN LAST THREE YEARS FY 2017-20 No. of Investments Savings, Year Proposals in Rs Million Rs Million 2017-18 14 90.82 432.63 2018-19 07 51.15 187.39 2019-20 07 14.56 112.55 Major energy saving project implemented in last three years: Installation of CDU-II MF & LGO Stripper column internals and LGO CR Exchanger : Investment made:5.7 Cr Annul saving 4500 TOE CDU-2 Main Fractionator is operated at high pressure due to the limitation in internals which is leading to substantial slippage of LGO product in RCO (Recovery @ 366°C approx. 25-30vol %). Also, due to the limitation in the pump around duty of LGO CR, reflux ratio requirement is high to minimize Naphtha generation within the limit of overhead water dew point. (Details covered in Innovative projects slides): YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth ENCON PROJECTS IMPLEMENTED IN 2017 - 18 Payback Investment in Savings S.N Project description Remarks period in Rs Millions Rs Millions Months Improving the performance of WGC of RFCCU turbines by upgradation of CCC 01 MP Steam saving 3 T/hr 0.50 35.33 0.17 to CCC+ for better and finer anti-surge control Tuning and upgradation of CCC to CCC+ 02 for better and finer anti-surge controlMP Steam saving 5 T/hr 5.73 62.82 1.10 (blow out valve-BOV) in MAB of RFCCU Reduction of WGC turbine load by absorption of heavier components from 03 Power saving 47 KWh 0.50 1.95 3.07 MF off gases by washing with HCN+debutanizer bottom Low pressure operation (Flash Zone pressure reduced from 2.9 to Installation of CDU-II MF & LGO Stripper 04 2.6 kg/cm2) & Reduction in RCO 56.51 105.99 6.40 Internals and LGO CR Exchanger yield (~3.0 wt% in both LS & HS mode) Cleaning of 8 No’s of Pre Heat Exchangers Improvement of ~10 °C is observed 05 11-E-10 A/B/C/D (Crude vs.
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