Bharat Oman Refineries Limited (BORL)STEAM TURBINE GENERATOR VHP steam 110 Kg/cm2 MP steam 18 Kg/cm2...

21st National Award

for “Excellence in Energy Management – 2020”

Bharat Oman Refineries Limited

(BORL)Bina, Madhya Pradesh

Rajesh Nandanwar – AVP

Nitin Tripathi– Manager, Krati Maloo –AM

BPCL Marketing Terminal

Kochi Refinery

Mumbai Refinery

Numaligarh Refinery

BPCL Refineries

Bina

Kota

Crude Oil From Middle East

Vadinar

Single Point Mooring (SPM) at Vadinar – VLCCs

1

2

3

Crude Oil Terminal & Pumping System (COT) Vadinar

Vadinar- Bina 935 km Crude pipeline (VBPL)

Delhi

Crude pipeline

Product pipelines

Advantageously placed to meet product requirements in high demand zone

BORL Facilities at a Glance

7.8 MMTPA Refinery at Bina

4

5

6

Bina Despatch Terminal (BDT)

Bina-Kota pipeline (BKPL) linking BPCL’s existing piping network (265 km)

BORL – subsidiary

company of BPCL,

with equity participation

from OQ

Refinery Configuration

Complex configuration, proven technologies, mid-distillate refinery

Process Capacities

An ISO 50001:2018 EnMS certified company

Refinery Process

Nelson Complexity Index – 11.58

Commercial production started - Jun 2011

STEAM

TURBINE

GENERATOR

VHP steam

110 Kg/cm2

MP steam 18 Kg/cm2To

Refinery

Power Steam

INSTALLED CAPACITY 99 MW 985 TPH

IMPORT FROM GRID CAPABILITY 100 MW

From Grid (220kv)

3 X 33 MW

Captive Power Plant General Overview

To Refinery

CFBC Boilers – 3 Nos

CFBC Boilers

MADE BY: BHEL

CAPACITY: 3 X 275 MT/hr

(Petcoke)

HP steam 40 Kg/cm2

LP steam 5 Kg/cm2

STGs

Utility Boiler

Net 160 TPH

4

Energy consumption overview (2017-2020)

Year

Thermal Energy

consumption

(Million KCal)

Electrical Energy

consumption

(Million KWh)

Total Energy

consumption

(MTOE)

Crude

processed

(TMT)

2019-20 5521788 782.8 619499.6 7912.91

2018-19 4002356 586.4 450663.3 5715.88

2017-18 4457851 613.8 498571.9 6707.90

5

Energy consumption overview (2019-20)

Year

Thermal Energy

consumption

(Million KCal)

Electrical Energy

consumption

(Million KWh)

Total Energy

consumption

(MTOE)

2019-20 5521788 782.8 619499.6

67321 (11%)

552179 (89%)

Annual Electrical energyconsumption

Annual Thermal energyconsumption

Thermal and Electrical consumption (MTOE) for FY2019-20

Specific Energy Consumption (SEC) -

Electrical & Thermal

80

90

100

110

2017-18 2018-19 2019-20

91.5

102.698.9

Specific Electrical Energy ConsumptionkWh/MT of Crude Processed

600

650

700

750

2017-18 2018-19 2019-20

665

700 698

Specific Thermal Energy Consumption kCal/kg of Crude Processed

Higher

Specific

energy from

FY 2018-19

due to

revamp

configuration

changes.

National Benchmarking

Specific Energy Consumption (SEC)

Refinery Specific Energy Consumption measured in MBTU/BBL/NRGF (MBN)

Source: PPAC, BEE, CII website

50

90

130

MB

N

Indian PSU Refineries & BORL

Indian PSU Refineries & BORL SEC

Source, BEE published Gazette of India (MBN-FY 2018-19)

69.25

67.02 69.2565.03

50

60

70

80

90

2017-18 2018-19 2019-20

MB

TU/B

BL/

NR

GF

BORL SEC

Sr. No. Project DetailsInvestment

(Lakhs)

Saving (Lakhs

KWH)

1

Installation of Power recovery turbine (PRT) in

Sulphur recovery unit (SRU) MP to LP PRDS

to recover the energy losses

1114 148.1

2

Energy saving by stopping CPP Export BFW

pump by interconnection between CPP Export

BFW pump and Utility Boiler (UB) BFW pump

62 7.7

3Energy saving by Installation of Variable fluid

coupling in 2 CFBC PA/SA fan378 47.5

Energy Conservation Measures Planned 2020-21

9

Energy Conservation Measures implemented in

last three years

Year No. Proposals

Savings InvestmentPayback

Period

FO

(MT/Yr)

Rs

(Lakhs/Yr)

Rs

(Lakhs)Months

2019-20 4 321 112 81 9

2018-19 9 24047 8519 7781 11

2017-18 12 4059 1310 1016 9

Total 25 28427 9941 8878 11

Any small saving in energy significantly impacts OP-Ex


(Lakhs)

Saving

(Lakhs/Yr)

Payback

(Months)

1

Stopping the dedicated CPP VAM

cooling water system by meeting its

cooling water requirement through

ACW system ,saves 15.829KW

power

20 7.1 34

2

Refinery cooling tower Fan A/B blade

and hub assembly replacement with

energy efficient blades, saves 25KW

power

14 14 12

Energy Conservation Measures Implemented 2019-20


(Lakhs)

Saving

(Lakhs/Yr)

Payback

(Months)

3

LVGO PDT (12-PA-CF-112) pump two

pump operation changed to one pump

operation by increasing the LVGO IR

pump(12-PA-CF-110) impeller diameter

, saves 110KW power

0 61 0

4

Energy saving by replacement of

Conventional light by energy efficient

LED light, saves 143 KW

47 30 19

Energy Conservation Measures Implemented 2019-20

Innovative Project 1:

Process Gas waste heat recovery in Hydrogen Plant

12

Objective:

Recovery of waste heat.

Preheating of DM water.

Reduce CPP deaerator steam consumption.

Trigger:

Cooling of process gas from 153 C using fin fans.

Heat loss to atm, can be captured for DMW heating.

Reduce power consumption in fin fans.

Project Detail:

Around 21Gcal/Hr heat is lost to atm during cooling using fin fans.

300 m3/hr DM water preheating from 45 C to 115 C is possible.

Reduction of 15 TPH LP steam used for pre-heating in deaerator.

Heat exchanger in parallel to fin fans is utilized for heat recovery.


Process Gas waste heat recovery in Hydrogen Plant

13

Benefits :

Steam saving- 15 TPH

AFC Power saving- 150KW

Investment - 4.5 Rs Cr

Monetary Savings - 31.7 Rs Cr/yr

Pay Back ~ 1.7 Month


Power Recovery Turbine in HCU feed pump

14

Objective:

Recovery of high pressure let-down energy.

Generation of power by providing PRT.

Trigger :

Let-down of 160 kg/cm2g to 30 kg/cm2g process fluid.

Pressure energy can be recovered by provision of PRT.

Project :

High pressure recovery turbine (HPRT) was installed in parallel to let-

down valve to convert this pressure energy in to power generation.

Recovered power from HPRT is utilized for driving feed pump by

generating power 850 KW.


Power Recovery Turbine in HCU feed pump

15

Benefits :

Power generated- 850 kW


Monetary saving - 4.67 Rs Cr/yr

Pay Back ~ 65 Month


Flare gas recovery through ring compressor

16

Objective:

Water ring compressor was required as part of revamp changes in DCU.

Integration of Flare gas recovery helped in reducing Opex & Capex.

Trigger :

WRC operates for 4 hrs only during 24 hrs Coke drum cycle.

Rest of the time, it can be utilized for flare gas recovery.

Project :

Water ring compressor installed as per revamp project due to increase in

Coke-drum pressure.

Compressor used for process requirement and flare recovery both by

providing two separate I/L & O/L line and providing separate XV in the

lines for different operation.

17

Benefits :

Monetary saving -9.93 Rs Cr/yr


Pay Back ~ 6.6 Month


Flare gas recovery through ring compressor

Technology Type of

EnergyOnsite/Offsite

Installed

Capacity (MW)Generation

(million kWh)

% of overall

electrical

energy

Electrical Solar Energy onsite 4.14 6.325 0.81

Utilization of Renewable Energy Sources

Solar panels installed at administrative building car parking in

FY 2019-20, having a capacity of 140 KW.

Solar panel on

car parking shed

Year2017-18 2018-19 2019-20

No of Project

implemented0 0 1

Capacity Addition

(MW)0 0 0.14

Investment made

(In Lakhs)0 0 65.8

Unit Total capacity

(MW)4 4 4.14


4 MW Solar Power Plant at BORL

generating 20000 units per day

10 kW Solar PV Panel in SV stations

of VBPL pipeline

Installed Solar Power based electric

fencing to refinery as well as

township boundary wall of 22 kms for

security purpose Installed solar panel

at Admin car parking.

Installed Solar Water heating system

Solar Wind hybrid power supply

system for Campus vide surveillance,

Wi-Fi and LED based street light.


S.N.Type of waste generated

Quantity of waste

generated (MT/Year) Disposal method

1 Oily sludge 292Recycled to Delayed

Coker Unit

2 Spent catalyst 425.37To recyclers for metal

recovery

3Empty barrels / containers

/liners20.38 To recyclers

4 Spent ion exchange resin 3.51To Secure disposal

facility

5 Waste residue containing oil 2.75To Secure disposal

facility

6 Spent carbon or filter media 2.72To Secure disposal

facility

7 Slop and used oil 15435Recycled along with

crude oil

Waste utilization and management (2019-20)

22

• Heater optimization, steam & power optimization and flare valve passing

survey etc.

• Encon measures likes Micro-turbine in SRU PRDS, Voith coupling in CPP

PA/SA fan IGV, ORC for low value heat recovery etc will result 5 MW of power

reduction.

t CO2 emission is calculated based on ISO 14064 -1 methodology.

GHG emission inventory trend

0.37(2485 TMT)

0.39 (2246 TMT)

0.38(2996 TMT)

0

0.1

0.2

0.3

0.4

0.5

0.6

2017-18 2018-19 2019-20

tCO

2/M

T o

f cr

ud

e

thro

ugh

pu

t

Best Practices on Energy Front in Green Supply

Chain

Management commitment to continual improvement in energy performance is

demonstrated by;

• bringing energy efficiency in the design stage,

• purchasing energy efficient equipment, based on life cycle cost.

• Certification of EnMS ISO 50001:2018 within shortest time.

• Steering committee formation for well structured reviews

• Promotion of participative energy conservation culture by launching platform

like RISE & Managing Director Award

• Certification of ISO 9001:2015, ISO 14001:2015, ISO 45001:2018

• Dedicated energy department – BEE certified Energy Manager

Transport of Raw Material:

• Use of Drag Reducing Agent (DRA) & VFD to reduce energy consumption in

pipeline & throughput maximization

Best Practices on Energy Front in Green Supply

Chain

Manufacturing & Storage :

• Use of energy efficient design - maxm heat integration

• Maximization of Hot Feed (85-94%), Condensate Recovery (80-85%)

• High efficiency fired heaters/boilers, Use of Glass APH, API 560

• Low emissions - Double seal in tanks & pumps, LDAR

• Use of renewable resources – Solar power plant, Solar water heater

• Use of APC for energy optimization, third party energy audit

• Hydrocarbon loss accounting as per IP method

• Participation in Global Benchmarking

• Fly ash brick is being utilized in all construction work.

• Extensive monitoring of high energy intensive equipment

• Ultrasonic flare flow meter in all units, VFDs in Fin Fans & ID/FD

Product Transportation: Maximized product evacuation though pipeline

Greening at BORL

Water Conservation:

Rain Water Harvesting pond with ground

recharge facility within the refinery

premises with solar lighting installation &

RWH pits in township are developed.

Recharge to groundwater ~ 85 TKL

Sink for GHG Emission:

200mtr area covered under greenbelt

3.5 Lakhs samplings in refinery &

35,000 sampling in township

2 Lakhs samplings in nearby villages

Dedicated Energy Department headed by

Energy Manager who is BEE certified

Energy Auditor

Each area has Energy Coordinator

Two tier mechanism of review: Energy

performance & energy improvement

schemes are monitored in

• Monthly review at unit level

• Quarterly review at Apex level chaired

by MD, BORL.

Encon Project Management Team is a cross

functional team

Energy Management Team

Monitoring and Reporting Practices

“To manage we have to control and to control we have to measure”

Sr.

No.Energy Performance Indicators

Monitoring

Frequency

1 Fuel & Loss Daily

2 Flare Loss Daily

3 Fired Heater Performance & CPP Performance Daily

4 Hot & Cold Feed Optimization Daily

5 Unit wise Specific Fuel, Power, Steam Consumption Daily

6 Equipment wise Steam Generation Daily

7 Refinery Steam Balance Daily

8 Refinery Specific Energy Consumption (MBN) Daily

9 Refinery Energy Intensity Index (EII) Daily

10 Hydrocarbon Loss Accounting Daily/ Monthly


Unit Flare monitoring graphic in DCS :


Unit Specific Energy Consumption (MBN) monitoring graphic in DCS :

30

ISO 50001:2018 Energy Management System (EnMS)

Certification

Long term vision on Energy efficiency

Refinery capacity enhancement from 7.8 MMTPA to 15 MMTPA

Refinery configuration study done by Technip FMC

Market study done by IDS (Industrial development price)

Implementation of Real Time Energy Optimizer (VM-ERTO)

Online Monitoring & Optimization of utilities.

Energy system online auditing.

Energy related Key performance indicator (KPI) calculation.

Online monitoring of emissions.

CO2 emission calculation.

Case study (What-if analysis) in offline mode.

Awards and Recognition

FY 2019-20:

• National CSR Leadership Award, 2020.

• Award from National Human Resource Development Network

(NHRDN)

• “Certificate of Recognition” by state government for exemplary work in

field of Rural Sports


FY 2018-19:

• Best ‘Refinery of the Year’ award conferred by FIPI.

• “Energy Efficient Unit” award by CII.

• National CSR Leadership Awards 2019.

• Silver Award under CSR category in ‘EXCEED AWARD 2018’.

• National Safety Council of India (NSCI) - Shrestha Suraksha

Puraskar.

• Certificate of Merit conferred by Indian Chemical Council for the

Year 2017 in recognition of efforts towards reduction in Energy

consumption.


Hon’ble President of India

Shri Ram Nath Kovind

conferring the ‘National

Energy Conservation

Award 2017’, Managing

Director, BORL Shri S S

Sunderajan receiving the

award at a ceremony

conducted in Vigyan

Bhavan, New Delhi on 14th

Dec 2017

Hon’ble President of India

Shri Ram Nath Kovind

conferring the ‘National

Energy Conservation

Award 2017’, Managing

Director, BORL Shri S S

Sunderajan receiving the

award at a ceremony

conducted in Vigyan

Bhavan, New Delhi on 14th

Dec 2017

Refinery of the Year Award 2017 (<9 MMTPA) - FIPI

BORLFuelling Nation…

Bringing Cheers

An ISO 9001, 14001, 45001 & 50001 company

Thank You

IMC Ramkrishna Bajaj National

Quality Award 2017 Refinery of the Year Award 2017 (<9 MMTPA) - FIPI

ICC Award 2017CII 19th National Award 2018 CII 18th National Award 2017

Bharat Oman Refineries Limited (BORL)STEAM TURBINE GENERATOR VHP steam 110 Kg/cm2 MP steam 18 Kg/cm2...

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