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. RCO) & 11- in CDU-1 Preheat post unit start- 1.60 50.87 0.38 E-05 A/B/C/D (Crude vs. Kerosene CR) up.
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 Cleaning of 7 No’s of Pre Heat Improvement of ~10 °C is Exchangers 16-E-13 A/B/C/D (Crude 06 observed in CDU-2 Preheat post 1.40 60.06 0.28 vs. LGO CR), 16-E-114 A&C (Crude vs. unit start-up. RCO) & 16-E-11B (Crude vs. LGO) 16-F-01 Stack temperature Convection Zone & APH Cleaning of 07 reduced by 65 °C (from ~250 °C 0.20 18.84 0.13 16-F-01 & 16-F-101 furnaces to ~175 °C) Improvement of ~10 °C is Pre heat Exchangers 31E- 08 observed in VDU-1 Preheat post 0.24 24.73 0.12 6AC/7/122AB cleaned unit start-up. Stack temperatures reduced by 09 Replacement of leaky APH of 31-F-02 22.94 3.76 73.30 25°C from 240 to 215°C Fouled HEx 37E-01A/B/E/F CIT improved by 20°C from 10 0.80 14.30 0.67 cleaned in VBU 273 to 293°C
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth ENCON PROJECTS IMPLEMENTED IN 2017 - 18
Investment in Savings Payback period S.N Project description Remarks Rs Millions Rs Millions in Months 32F01 furnace convection and radiation Reduction in stack temp by 11 0.20 7.76 0.31 zone external cleaning 60°C from 455 to 390°C Savings of Energy by routing of savings in LP steam - 1.71 12 atomizing air cooler hot DM water T/h, stopping pump - 3.7 KW, 0.10 23.44 0.05 directly to De-aerator in GT-2 cooling water - 130 m3/h GT – 1 Atomizing Air cooler hot DM line 13 0.10 18.07 0.07 up to De-aerator HRSG Boiler Feed line up was done from only one De-aerator by opening BFW 14 stopping pump - 220 KV NIL 4.71 - discharge interconnection between both De-aerators Total 90.82 432.63
• All the planned schemes could be executed and implemented due to total refinery shutdown
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth ENCON PROJECTS IMPLEMENTED IN 2018 - 19
Payback Investment in Savings S.N Project description Remarks period in Rs Millions Rs Millions Months H2 Recovery from OHCU HP Rich Amine Equivalent Energy savings against 1 (H2 recovery potential is 75.47 Kg/h 49.70 7.62 78.23 H2 recovered equivalent to 0.6 MMTPA) Stripping Steam to LGO: actual Stoppage of Stripping steam to LGO & 2 savings 580 kg/hr vs. envisaged NIL 12.10 - HGO stripper in CDU I 760 kg/hr Stripping Steam to HGO: actual Stoppage of Stripping steam to LGO & 3 savings 300 kg/hr vs. envisaged NIL 6.30 - HGO strippers in CDU II 685 kg/hr
1% Improvement in Boiler-4 Efficiency 4 Insulation repaired during M&I 0.50 46.64 0.13 by Insulation Repair
Passing valves Identified and Survey of PSV/CV connected to flare for rectified: 47 no's with total passing 5 0.36 105.41 0.04 identification of passing valves flow 42.16 T/day
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth ENCON PROJECTS IMPLEMENTED IN 2018 - 19
Payback Investment in Savings S.N Project description Remarks period in Rs Millions Rs Millions Months
Total air leaks Identified and rectified: 700 6 ARC for Compressed Air leak 0.39 8.45 0.55 no's with flow 1485.7 Nm3/hr
Total air leaks Identified and rectified: 28 no's 7 ARC for Nitrogen leak 0.20 0.87 2.77 with flow 67.44 Nm3/hr,
Total 51.15 187.39
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth ENCON PROJECTS IMPLEMENTED IN 2019 - 20
Payback Investment Savings S.N Project description period in in Rs Millions Rs Millions Months
1 Replacement of 30 nos of LT motors with energy efficient motors 2.30 2.83 9.76
Excess air optimization of the Heater 11-F- 01 by replacement of O2 2 1.46 40.81 0.43 Analyzer with TDLS O2 analyzer
Excess air optimization of the Heater 82-F- 01 by replacement of O2 3 1.46 2.76 6.35 Analyzer with TDLS O2 analyzer
Excess air optimization of the Heaters 91- F-01 and 91-F-02 by 4 2.92 14.06 2.49 replacement of O2 analyzer with TDLS O2 analyzer
5 Recovery of steam/condensate loss in refinery complex,20TPH 0.50 19.30 0.31
6 Tube inserts for 2 no’s of HE of CDU-II. 5.92 19.69 3.61 Total 15.16 112.55
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 6.INNOVATIVE PROJECTS IMPLEMENTED IN LAST THREE YEARS FY 2017-2020
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth INNOVATIVE PROJECT- 01 Name of the Project: Reduction of CDU-II MF column pressure by installation of high efficiency trays in MF & LGO Stripper during Dec’17 TRSD to recover more LGO.
Brief Description: CDU-2 Main Fractionator was operated at high pressure @ 1.9- 2.1 kg/cm2 due to the limitation in MF internals which is leading to substantial slippage of LGO product in RCO (Recovery @ 366°C approx. 25vol %).
Benefits of Low pressure operation of CDU-II MF column:
Better RCO recovery Increase in Middle distillate (SKO+LGO) Lower Pressure drop Reduced flaring
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth INNOVATIVE PROJECT- 01 Modifications carried out: • Replacement of CDU-II MF & LGO stripper internals, supplied by M/s Sulzer) •Total 16 no. of trays, 3 packings, 2 distributors, Feed inlet device & 3 nozzle change in MF •Replacement of existing trays (05 nos.) with New Sulzer high performance trays •Two new LGO CR vs Crude exchangers (in PHT-III i.e. post PF PHT) to recover 3.7 MMKcal/h of heat from increased LGO CR flow
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth INNOVATIVE PROJECT- 01
Benefits Achieved:
RCO recovery improved from 25-30 vol% to 12-16 vol% Increase in Middle distillate (SKO+LGO) yield by 12 wt% (47 wt% against base level of 35 wt%) Top pressure reduced from 2.1 to 1.5 kg/cm2
Annual Savings: 1060 Rs Lacs;
Investment made: 565.06 Rs Lacs
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth INNOVATIVE PROJECT- 02 Name of the Project: Tube Inserts installation in CDU-II exchangers for preheat sustenance in Aug’2019
Problem: Frequent fouling of pre-heat exchangers resulting in loss of T’put and waste heat recovery
• Normally, heat exchangers in CDU-II are cleaned during every M&I shutdown and based on the survey done quarterly
• However, sustenance of performance and pre-heat availability from the cleaned exchanger is very short because of fast fouling
• Tube inserts installed in Pre-heat exchangers 114A&C which are just before fired heaters
• Shell side fluid :Crude • Tube side fluid: RCO
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth INNOVATIVE PROJECT- 02
Benefits of Installation of Turbotal:
• The on line rotation of the Turbotal due to fluid flow through tubes • Mechanical effect against fouling • Avoids the deposition of a thick fouling layer inside tube wall • Reduced pressure drop • The rotation of Turbotal increases the turbulence in the tube side flow • Increased heat transfer coefficient on the tube side. • Optimal use of the heat exchangers and reduces the outlet Delta T between Start of Run and End of Run. HTC increased by 17-20% and sustained at higher than clean case.
Annual Savings: 240.34 Rs Lacs
Investment made: 59.22 Rs Lacs
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth INNOVATIVE PROJECT- 03 Scheme: Utilization of GT1/2 Compressed air discharge cooler waste heat for DM water heating
Investment made: Nil Implemented in 2017
Benefits: • Circulating Pump and cooler removed • Reduced CW requirement dismantled • Reduced CT load
After Implementation Before Implementation
Annual Savings: 29 Rs Lacs
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 7.UTILISATION OF RENEWABLE ENERGY SOURCES
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth RENEWABLE ENERGY SOURCES – SOLAR ENERGY
Annual Energy Annual Energy Annual Energy Installed Replacement of Electrical Energy Generated in Generated in Generated in Capacity with Renewable Energy 2017-18 2018-19 2019-20 (MW) (Million kW) (Million kW) (Million kW) Solar (PV) - Onsite Gen 1.96 0.11 0.14 0.45
Installation location & capacity of solar panels: Installed Installed Capacity Sl No ZONES Location Sl No ZONES Location Capacity (Kwp) (Kwp) 1 LOB 3A 20.5 15 DHDS Reservoir-2 90 SS # 3 + 3 16 OFFSITE CISF Barrack 50 2 LOB 61 Ext 17 OFFSITE S/S-19 50 3 offsite 4 41 18 FOB S/S-20 50 4 offsite 6A 20.5 19 FOB S/S-16 30 5 DHDS SS - 9 & 15 71 20 LOB S/S-17 30 6 LOB 13 20.5 21 OHCU S/S-18 200 7 Offsite 14 20.5 Total 500 8 DYIP 21 273 9 DYIP 22 50 10 DYIP 23 152 11 DYIP 24 91 12 IMA TOWNSHIP 31 13 HOSPITAL TOWNSHIP 61 Kendriya 14 TOWNSHIP 87 Vidyalaya Total 1000
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 8. WASTE UTILIZATION AND MANAGEMENT
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth WASTE MANAGEMENT
Quantity of S.N Type of waste Generated waste generated Disposal method (MT/year) 2017-18 01 Spent RFCCU catalyst 1173 02 Spent adsorbent 7.96 To secured landfill through PCB authorized TSDF(treatment Oil soaked waste mineral 03 210 storage and disposal facility) agency wool 04 Residual oily sludge 3350 2018-19 01 Spent RFCCU catalyst 1219 To secured landfill through PCB authorized TSDF agency 02 Spent adsorbent 51.71 Oil soaked waste mineral 03 221 wool Incineration through TSDF agency 04 Residual oily sludge 406 For co-processing in CPCB authorized cement plant 05 Residual oily sludge 4995 (Ambuja Cement) 06 Spent resin 22 To secured landfill through TSDF agency 07 Spent RO membrane 21 To secured landfill through TSDF agency
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth WASTE MANAGEMENT
Quantity of waste S.N Type of waste Generated Disposal method generated (MT/year) 2019-20 01 Spent RFCCU catalyst 839 To secured landfill through PCB authorized TSDF agency 02 Spent adsorbent 356 03 Oil soaked waste mineral wool 788 Incineration through TSDF agency 04 Residual oily sludge 356 For co-processing in CPCB authorized cement plant (Ambuja 05 Residual oily sludge 5923 Cement) 06 Spent resin 9 To secured landfill through TSDF agency 07 Spent hydro processing catalysts 312 Through MSTC to authorized recyclers for metal recovery
Other Initiatives taken for waste utilization & management: 1.Food Waste: Use of food waste based bio-gas generator with 500Kg capacity commissioned in Dec'19 for use in industrial canteen. 2.Waste Paper: Annually about 1500kg waste paper donation to Vivekananda mission for manufacturing recyclable paper products like files, envelopes etc. 3.Spent RO membranes: Utilization of spent RO membranes for barricading local water bodies and improving aesthetics. 4. Bio-gas generator(100 kg capacity) : installed for use by Vivekananda school. Manure generated is used for horticulture purpose. YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 9. GHG INVENTORISATION
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth GHG (Absolute Emission trend)
2300000 2268021 2250808 2227456 2200000
2110364 2100000 2079000 2070089 2056554 2071648 2054633
2000000
1934698
1900000
1800000
1700000 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20
GHG emissions MT of CO2 eq / Year
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth GHG EMISSION PER TON OF PRODUCT
Total Total (kgCO2 / Ton of YEAR Remarks product,TMT Final Product) 2016-17 6793 304.74 2017-18 6820 301.25 2018-19 7321 283.94 CO2 emissions higher on account of lower 2019-20 5734 337.39 capacity utilization of the refinery
Target (short term/long term) for CO2 emission reduction and action plan:
CO2 emission Target Year for S.N Scheme reduction completion 01 Replacement of fuel oil with LNG 18900 2022 02 Recovery of Hydrogen from Refinery Off-gases 17325 2020 03 Hot feed to KHDS unit 472.5 2020 04 Fan less cooling tower installation in GT 787.5 2020 05 Crude Preheat Temperature improvement BY 9 DEG C in CDU-2 18900 2021 Total 56385
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth EMISSIONS DISCLOSURE TO PUBLIC
Continuous Ambient Air quality monitoring
Station inside Refinery to monitor SO2, NOx,
PM10, PM2.5, Ammonia, Benzene, Ozone and CO. This data being shared online to CPCB and SPCB server and at Refinery Gate
Unit Limit Refinery Township
3 PM10 µg/m 60 42-55 30-44 3 PM2.5 µg/m 40 25-35 16-22
3 SO2 µg/m 50 8-15 5-8
3 NOx µg/m 40 15-25 21-33 CO µg/m3 2 0.5-0.8 0.4-0.7
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth STACK ANALYSER CONNECTIVITY TO CPCB SERVER
Stack emission parameters (SO2, NOx, CO and PM) are monitored online and SMS alert generated in case of any deviation.
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 10. GREEN SUPPLY CHAIN MANAGEMENT
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth GREEN SUPPLY CHAIN MANAGEMENT
Annual Year of Investment S.N Projects Implemented capacity, commissioni Made Benefits Achieved Remarks MMTPA ng (Rs In Million)
LPG is being dispatched to Budge Reduction in CO2 LPG Pipeline Transfer facility ex Budge BP, Kalyani BP, Durgapur emissions by 12.5 01 Haldia Refinery to Paradip - Haldia- 0.67 Sep’2019 28.3 BP directly from Haldia Refinery in Thousand metric tonnes Durgapur pipeline mode via PHBPL LPG annually pumping station.
Expected Reduction in CO2 Haldia-Barauni petroleum products commissionin emissions by 99 02 3.40 128.0 Presently under execution stage pipeline g by FY Thousand metric tonnes 2022-23 annually
Company has green purchase policy. Our recent purchase PO details mentioned below.
SN PO number Value/qyt/item Remarks Motor with Efficiency Class - IE3 as per 1 26444826 dated 08.06.2020 Rs. 307,000.00 IS 12615(2011)& IS 15999 (Part 2/Sec 1) has been purchased
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 11. Team work, Employee Involvement & Monitoring
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth ENCON Monitoring System at Haldia Refinery
2. Daily/Monthly – Monitoring 1. Monitoring Tools available S.N Monitoring Activity PRO-II Daily/Monthly Activity 01 Unit Specific Energy Consumption
HRTI Energy 02 Energy Intensive Equipment's – Heater, compressor performance Audits HeX Monitoring model 03 Steam let down, flare, Pressure recovery Turbine Tools 04 Fuel & Loss 06 Specific Energy Consumption (MBN) Online steam leak Dashboard reporting 07 Energy Intensity Index (EII) system
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth ANNUAL PROGRAMS ON CREATING AWARENESS ON ENERGY CONSERVATION
Annual budget for Energy conservation awareness: ~ 7 to 10 Rs Lacs Celebrated every year: 16th Jan to 15th Feb
Street Plays in Local Community for spreading the message of Energy Conservation at various places viz Schools / Township Parks/MARKETS/colonies etc
Quiz Competition for School Students/ Employees /House wives
Walk Rally by school children, IOCL employees and CISF dependents
Energy Audit by CHT nominated persons
Training program by external faculty
Drawing competition for school students.
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth PROJECTS IMPLEMENTED THROUGH KAIZENS – SUPERVISOR LEVEL
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth PROJECTS IMPLEMENTED THROUGH KAIZENS – WORKER LEVEL
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 12. IMPLEMENTATION OF ISO 50001
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth IMPLEMENTATION OF ISO 50001
Energy policy exists Internal audit completed Pre-audit phase completed. Certification audit– expected completion by Sep’2020
EnCon Project budget allocation %
Total turnover of the refinery in FY 2019-20 (Rs. Million) 233198 Amount invested in EnCon Projects FY 2019-20 (Rs. Million) 14.56 Investment % 0.0062% Total expenditure on energy projects since last 3 years (Rs Million) 156.52
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 13. OTHER INNOVATIVE TECHNOLOGIES IMPLEMENTED
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 1.Installation of fan less Cooling Tower for GT
Scheme: Installation of fan less Cooling Tower for GT • Installation Cost : 1.05 Rs Cr • Flow:500m3/h • CT fan power:130KW • Construction almost completed, Commissioning expected in a month time
Advantages of Fanless Cooling Towers: • No frills • No fan required • The louvers are used as the side wall of the cooling tower to restrict the water spillage. • The hot water sprayed in the top of the cooling tower with spray nozzles. • No huge amounts of noise • Minimum drift losses • Less maintenance cost • Pressure difference is created by water spray through nozzles, allowing cool air ingress into the tower, hot air exit from the tower. Fuel savings: 250 TOE/Yr
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 2.Use of drone for monitoring furnace and flare stacks for thermal imaging Use of Industrial Drone for monitoring Flare and furnace stacks for thermal imaging heat loss and insulation damage survey in FY2018-19
remote visual inspection using unmanned drone
The drone utilized was equipped with high resolution visual as well as thermal imaging camera
Provides high quality image, video and thermograph of the inaccessible location of the tall structures.
For assessing the health condition of the flare tips, stacks and refractory lining
Will help us plan for repair or replacement in more efficient manner.
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 3.Use of TDLS analyzers for furnace stack O2 measurement
Conventional O2 analyzers collect localized sample and Measure localized O2 readings
TDLS analyzers:
TDLS O2 analyzer measures cross sectional avg O2 % Better accuracy of O2 reading and there by Furnace control Non contacting measurement Better control of excess air
TDLS analyzers installed in: CDU-1/CDU-2,VDU-1,VDU-2,OHCU furnaces in FY2019-20
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 14. LONG TERM VISION ON EE
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth LONG TERM VISION ON EE
Long Term Vision on Specific Energy Consumption(MBN): 55
Apart from Schemes mentioned earlier, the following are under discussion for reducing MBN further
Envisaged S. N ENCON Scheme TOE/Yr 01 Boilers modification for efficiency improvement 10000 Installation of hot separator in OHCU to produce M.P. Steam from Reactor Effluent 02 9300 & also reduction in reactor effluent air cooler duty 03 Replacement of Full condensing Turbine of MAB to motor 12000 04 Replacement of Full condensing Turbine of WGC to motor 4400 05 Combined AVU instead of present 2 CDUs and 2 VDUs 55000 06 electrica heat tracing instead of steam tracing 4500 Total 95200
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth 15. AWARDS & ACCOLADES
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth AWARDS & ACCOLADES
SNName of awardreceived Remarks 1 Won the Director (HR) Trophy for “Best CSR Unit” among 31 establishments across IndianOil at IndianOil CSR Conclave held at Digboi. FY 2019-20
2 Won “Best Swatch Establishment Award” for Refinery Division for outstanding contribution to Swatch Bharat Mission during Swatchhata Pakhwada. FY 2019-20
3 “TOLIC award” for 2018-19 in the field of best implementation of official language under aegis of Ministry of Home Affairs, Govt. of Indian. FY 2019-20 4 Haldia Refinery has won the prestigious “Suraksha Puraskar” (Bronze trophy & certificate) in Group –A under the manufacturing Sector from National Safety Council of India for the year 2016 on Thursday, the 20th April, 2017 5 Haldia Refinery has been conferred Best Performance Award in “Carbon Di-Oxide Emission” under Refineries without Natural Gas category. FY 2017-28
6 Haldia Refinery has been awarded OISD Award (2016-17) under “Refineries and other processing plant” category.
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth AWARDS & ACCOLADES
SNName of awardreceived Remarks 7 Received Golden Peacock Occupational Health & Safety Award-2016 by Institute of Directors
8 Received the prestigious National Safety Award – 2014 by DGFASLI, Government of India. 9 Received International Safety Award - 2016 achieved from British Safety Council with ‘Merit’. 10 Received CII Excellence Award in Safety with four Star rating, by CII Eastern Region. 11 Received 17th National Award for Excellence in Energy Management 2016 from CII on 24th Aug 2016 at Hyderabad
12 Haldia Refinery was recognized for best performance in Carbon dioxide Emission Awards (2014- 15) under category of Refineries without natural gas on 7th Sep 2016 during 20th RTM at Gandhinagar. 13 Accreditation Certificate was issued by National Accreditation Board for Testing and Calibration Laboratories (NABL) on 18.10.2016 in the wake of the onsite assessment of Quality Control Laboratory,
14 First prize in the Oil & Gas Conservation Award for Furnace/ Boiler Insulation Effectiveness 2013-14
15 Conferred with Energy Conservation award 2012
16 Conferred with the Greentech Environment Excellence Award 2011 for environment management
YEAR OF DIGITALISATION Accelerating Efficiency, Empowering Growth